scholarly journals Finite Element Modeling and Simulation of Machining of Titanium Alloy and H13 Tool Steel Using PCBN Tool

2013 ◽  
Vol 392 ◽  
pp. 36-40 ◽  
Author(s):  
S. Sulaiman ◽  
A. Roshan ◽  
S. Borazjani
Keyword(s):  
Finite Element ◽  
Titanium Alloy ◽  
High Temperature ◽  
Stress Distribution ◽  
Finite Element Modeling ◽  
Tool Steel ◽  
Metal Cutting ◽  
Cutting Tool ◽  
Tool Material ◽  
Element Modeling

This paper deals with finite element modeling (FEM) and simulation of machining of titanium alloy and H-13 tool steel. Titanium alloys are very suitable for airframe manufacture and aircraft as H-13 uses forging dies and machined die casting. The machinability of both metals was evaluated by high temperature and tool wear. Finite element simulation was performed with ABAQUS explicit software to predict cutting temperature and stress distribution during metal cutting process. The purpose of this study was evaluation the performance of PCBN cutting tool material on machining of titanium alloy and H-13. It was found that PCBN tool can resistant well against high thermal shocks, high temperature and stress distribution when machining difficult to cut materials. The results can give a better understanding of cutting tool material for metal cutting process.

Computational Machining of Titanium Alloy—Finite Element Modeling and a Few Results

1996 ◽  
Vol 118 (2) ◽  
pp. 208-215 ◽  
Author(s):  
T. Obikawa ◽  
E. Usui
Keyword(s):  
Finite Element ◽  
Titanium Alloy ◽  
Finite Elements ◽  
Finite Element Modeling ◽  
Metal Cutting ◽  
Shape Change ◽  
Geometrical Nonlinearity ◽  
Deformation Analysis ◽  
Element Modeling ◽  
Serrated Chips

A Finite element modeling was developed for the computational machining of titanium alloy Ti-6Al-4V. The chip formation in metal cutting is one of the large deformation problems, thus, in the formulation of the elastic-plastic deformation analysis, geometrical nonlinearity due to the large shape change of the finite elements was taken into account and the over-constraint of incompressibility on the deformation of ordinary finite elements in the plastic range was relaxed to make the elements deformable as a real continuum. A ductile fracture criterion on the basis of strain, strain rate, hydrostatic pressure and temperature was applied to the crack growth during the chip segmentation. The temperature field in the flowing chip and workpiece and the fixed tool was calculated simultaneously by an unsteady state thermal conduction analysis and the remeshing of tool elements. The serrated chips predicted by the computational machining showed striking resemblances in the shape and irregular pitch of those obtained by actual cutting. The mean cutting forces and the amplitude of cutting force vibration in the computational machining were in good agreement with those in the actual machining.

Investigation on Chip Formation during Machining Using Finite Element Modeling

2012 ◽  
Vol 505 ◽  
pp. 31-36 ◽  
Author(s):  
Moaz H. Ali ◽  
Basim A. Khidhir ◽  
Bashir Mohamed ◽  
A.A. Oshkour
Keyword(s):  
Finite Element ◽  
Tool Wear ◽  
Finite Element Modeling ◽  
Chip Formation ◽  
Cutting Tool ◽  
Chip Morphology ◽  
Machining Process ◽  
Element Modeling ◽  
Segmented Chip ◽  
Cutting Speeds

Titanium alloys are desirable materials for aerospace industry because of their excellent combination of high specific strength, lightweight, fracture resistant characteristics, and general corrosion resistance. Therefore, the chip morphology is very important in the study of machinability of metals as well as the study of cutting tool wear. The chips are generally classified into four groups: continuous chips, chips with built-up-edges (BUE), discontinuous chips and serrated chips. . The chip morphology and segmentation play a predominant role in determining machinability and tool wear during the machining process. The mechanics of segmented chip formation during orthogonal cutting of titanium alloy Ti–6Al–4V are studied in detail with the aid of high-speed imaging of the chip formation zone. The finite element model of chip formation of Ti–6Al–4V is suggested as a discontinuous type chip at lower cutting speeds developing into a continuous, but segmented, chip at higher cutting speeds. The prediction by using finite-element modeling method and simulation process in machining while create chips formation can contribute in reducing the cost of manufacturing in terms of prolongs the cutting tool life and machining time saving.

Pressure-Containing Sleeve Alternatives

2006 ◽  
Author(s):  
Robert B. Lazor ◽  
Brock Bolton ◽  
Julian Florez ◽  
Carlos Nieves
Keyword(s):  
Finite Element ◽  
Stress Concentration ◽  
Stress Distribution ◽  
Finite Element Modeling ◽  
Operating Pressure ◽  
Element Modeling ◽  
Expected Performance ◽  
Contour Plots ◽  
Steel Grades ◽  
Different Thickness

The work described in this paper was completed to assess the expected performance of various repair sleeve configurations on an NPS 30, Grade X70 pipeline. A total of ten sleeve variations were studied, and these included sleeve-on-pipe, sleeve-over-collar, and sleeve-over-double collar configurations. The comparisons were based on the stress results of axisymmetric finite element modeling of the sleeve geometries, and included examining sleeves with different thickness, models with and without a gap between the sleeve and the pipe, and cases in which the annulus between the sleeves and pipe were either pressurized or not pressurized. Complementary tasks involved with this work included the specification of recommended epoxy materials and steel grades for reinforcing sleeves. The results of the analyses are presented in terms of contour plots of stress at the maximum operating pressure of the pipe, showing the general stress distribution and indicating areas of stress concentration. This study demonstrates how the loads vary amongst the different sleeve types, and shows how variations in geometry and loading conditions between models affect the operating stresses.

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