Finite Element Simulation of Cutting Forces in Orthogonal Machining of Titanium Alloy Ti-6Al-4V

2014 ◽  
Vol 474 ◽  
pp. 192-199 ◽  
Author(s):  
Ladislav Kandráč ◽  
Ildikó Maňková ◽  
Marek Vrabel' ◽  
Jozef Beňo
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Cutting Forces ◽  
Orthogonal Cutting ◽  
Experimental Studies ◽  
Cutting Speed ◽  
Rake Angle ◽  
Simulation Software ◽  
Tool Geometry ◽  
Element Method

In this paper, a Lagrangian finite element-based machining model is applied in the simulation of cutting forces in two-dimensional orthogonal cutting of titanium Ti-6Al-4V alloy. The simulations were conducted using 2D Finite Element Method (FEM) machining simulation software. In addition, the cutting experiments were carried out under the different cutting speed, feed and tool geometry (rake angle, clearance angle and cutting edge radius). The effect of cutting speed, feed and tool geometry on cutting force were investigated. The results obtained from the finite element method (FEM) and experimental studies were compared.

Micro Machining Simulation Analysis by Finite Element Method

2013 ◽  
Vol 712-715 ◽  
pp. 575-578
Author(s):  
Zhan Min Yin ◽  
Yu Juan Dai
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Simulation Analysis ◽  
Cutting Speed ◽  
Failure Criteria ◽  
Rake Angle ◽  
Depth Of Cut ◽  
Micro Machining ◽  
Machining Processes ◽  
Element Method

Micro machining becomes more and more important with the tendency of miniaturization of components used in various fields from military to civilian applications. The finite element method software Abaqus is used to model the nonlinear thermal force coupled elastic-plastic micro machining processes. Relatively systematic simulation analysis has been introduced based on the model combining the Johnson-Cook failure criteria, element deletion strategy etc. It reveals that the size effect is dominant while the depth of cut reaches the cutting edge radius. The rake angle plays more important roles on the micro machining than that of the cutting speed.

Cutting Tool Geometry and Parameters Effects on the Force and Temperature in Turning Steel 1040 Using Finite Element Analysis

2012 ◽  
Vol 548 ◽  
pp. 465-470
Author(s):  
Asaad A. Abdullah ◽  
Usama J. Naeem ◽  
Cai Hua Xiong
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Cutting Forces ◽  
Metal Cutting ◽  
Cutting Speed ◽  
Heat Rate ◽  
Cutting Parameters ◽  
Rake Angle ◽  
Tool Geometry ◽  
Element Analysis

In recent years, applications have been proven finite-element method (FEM) in metal-cutting operations to be effective process in the study of cutting and chip formation. In this study, the simulation results are useful for both researchers and machine tool manufacturers for improving the design of cutting parameters. Finite-element analysis (FEA) that used in this study of simulation the cutting parameters and tool geometries effects on the force and temperature in turning AISI 1040. The simulation parameters that used in this study are cutting speed (75 - 300 m/min),feed rate (0.2 mm/rev), cut depth (0.75-1.5 mm), and rake angle (0-20 °). The results of cutting forces were (240 – 520 N), the temperature were (300-420 °C), and the heat rate (14202.3-83772.8 W/mm3) on the cutting edge. The simulation process also show that the increase of cutting speed leads to decrease in the cutting forces, while it has increasing in temperature, and heat rate. Also, the results show that the increase of cutting depth associated increase the cutting force only.

scholarly journals Finite Element Prediction for the Internal Stresses of (Ti,Al)N Coatings

2016 ◽  
Vol 61 (1) ◽  
pp. 149-152 ◽  
Author(s):  
L.W. Żukowska ◽  
A. Śliwa ◽  
J. Mikuła ◽  
M. Bonek ◽  
W. Kwaśny ◽  
...  
Keyword(s):  
Finite Element Method ◽  
Computer Simulation ◽  
Finite Element ◽  
Experimental Studies ◽  
Single Layer ◽  
Internal Stresses ◽  
Pvd Coatings ◽  
Properties Of Coatings ◽  
Gradient Coatings ◽  
Element Method

The general topic of this paper is the computer simulation with use of finite element method (FEM) for determining the internal stresses of selected gradient and single-layer PVD coatings deposited on the sintered tool materials, including cemented carbides, cermets and Al2O3+TiC type oxide tool ceramics by cathodic arc evaporation CAE-PVD method. Developing an appropriate model allows the prediction of properties of PVD coatings, which are also the criterion of their selection for specific items, based on the parameters of technological processes. In addition, developed model can to a large extent eliminate the need for expensive and time-consuming experimental studies for the computer simulation. Developed models of internal stresses were performed with use of finite element method in ANSYS environment. The experimental values of stresses were calculated using the X-ray sin2ψ technique. The computer simulation results were compared with the experimental results. Microhardness and adhesion as well as wear range were measured to investigate the influence of stress distribution on the mechanical and functional properties of coatings. It was stated that occurrence of compressive stresses on the surface of gradient coating has advantageous influence on their mechanical properties, especially on microhardness. Absolute value reduction of internal stresses in the connection zone in case of the gradient coatings takes profitably effects on improvement the adhesion of coatings. It can be one of the most important reasons of increase the wear resistance of gradient coatings in comparison to single-layer coatings.

Numerical Analysis of Residual Stresses and Distortions in Aluminium Alloy Welded Joints

2015 ◽  
Vol 809-810 ◽  
pp. 443-448 ◽  
Author(s):  
Tomasz Kik ◽  
Marek Slovacek ◽  
Jaromir Moravec ◽  
Mojmir Vanek
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Aluminium Alloy ◽  
Thermal Cycle ◽  
Technology Development ◽  
Welding Process ◽  
Simulation Software ◽  
Structure Knowledge ◽  
Welding Processes ◽  
Element Method

Simulation software based on a finite element method have significantly changed the possibilities of determining welding strains and stresses at early stages of product design and welding technology development. But the numerical simulation of welding processes is one of the more complicated issues in analyses carried out using the Finite Element Method. A welding process thermal cycle directly affects the thermal and mechanical behaviour of a structure during the process. High temperature and subsequent cooling of welded elements generate undesirable strains and stresses in the structure. Knowledge about the material behaviour subjected to the welding thermal cycle is most important to understand process phenomena and proper steering of the process. The study presented involved the SYSWELD software-based analysis of MIG welded butt joints made of 1.0 mm thickness, 5xxx series aluminium alloy sheets. The analysis of strains and the distribution of stresses were carried out for several different cases of fixing and releasing of welded elements.

Finite Element and Experimental Analysis of Edge Defects Formation during Orthogonal Cutting of SiCp/Al Composites

2012 ◽  
Vol 500 ◽  
pp. 146-151 ◽  
Author(s):  
Ning Hou ◽  
Li Zhou ◽  
Shu Tao Huang ◽  
Li Fu Xu
Keyword(s):  
Finite Element ◽  
Chip Formation ◽  
Defect Formation ◽  
Orthogonal Cutting ◽  
Cutting Speed ◽  
Rake Angle ◽  
Critical Transition ◽  
Cutting Depth ◽  
Edge Defect ◽  
Edge Defects

In this paper, a finite element method was used to dynamically simulate the process of the edge defects formation during orthogonal cutting SiCp/Al composites. The influence of the cutting speed, cutting depth and rake angle of the PCD insert on the size of the edge defects have been investigated by using scanning electron. According to the simulated results, it can be provided that the cutting layer material has an effect on transfer stress and hinder the chip formation in the critical transition stage, and the critical transition point and distance are defined in this stage. The negative shear phenomenon is found when the chip transit to the edge defects in the flexure deformation stage, so the process of the chip formation is the basis of the edge defects formation. In addition, the relationship between the nucleation and propagation direction of the crack and the variation of the edge defect shape on the workpiece was investigated by theory, and it found that the negative shear angle formation is the primary cause of the edge defect formation. A mixed mode crack is found in the crack propagation stage. The sizes of edge defects were measured by the experiment and simulation, and the edge defect size decrease with the increasing of tool rake angle, while increase with increasing cutting depth and cutting speed.

scholarly journals Sensitivity Analysis of the Tetrapolar Electrical Impedance Measurement Systems Using COMSOL Multiphysics for the non-uniform and Inhomogeneous Medium

2016 ◽  
Vol 64 (1) ◽  
pp. 7-13 ◽  
Author(s):  
Onic Islam Shuvo ◽  
Md Naimul Islam
Keyword(s):  
Finite Element Method ◽  
Sensitivity Analysis ◽  
Finite Element ◽  
Inhomogeneous Medium ◽  
Electrical Impedance ◽  
Impedance Measurement ◽  
Simulation Software ◽  
Comsol Multiphysics ◽  
Sensitivity Distribution ◽  
Element Method

One of the major problems with Electrical Impedance Tomography (EIT) is the lack of spatial sensitivity within the measured volume. In this paper, sensitivity distribution of the tetrapolar impedance measurement system was visualized considering a cylindrical phantom consisting of homogeneous and inhomogeneous medium. Previously, sensitivity distribution was analysed analytically only for the homogeneous medium considering simple geometries and the distribution was found to be complex1,2. However, for the inhomogeneous volume conductors sensitivity analysis needs to be done using finite element method (FEM). In this paper, the results of sensitivity analysis based on finite element method using COMSOL Multiphysics simulation software are presented. A cylindrical non-uniform, inhomogeneous phantom, which mimics the human upper arm, was chosen to do the experiments by varying different parameters of interest. A successful method for controlling the region of interest was found where the sensitivity was maximum. Refining the finite element mesh size and introducing multifrequency input current (up to 1 MHz) this simulation method can be further improved.Dhaka Univ. J. Sci. 64(1): 7-13, 2016 (January)

A Model for the Prediction of Form Errors in Face Milling and Turning

1999 ◽  
Author(s):  
Luc Masset ◽  
Jean-François Debongnie ◽  
Sylvie Foreau ◽  
Thierry Dumont
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Cutting Forces ◽  
Experimental Validation ◽  
Industrial Applications ◽  
Face Milling ◽  
The Finite Element Method ◽  
Form Errors ◽  
Error Computation ◽  
Element Method

Abstract A method is proposed for predicting form errors due to both clamping and cutting forces in face milling and turning. It allows complex tool trajectories and workpiece geometries. Error computation is performed by the finite element method. An experimental validation of the model for face milling is presented. Two industrial applications are produced in order to demonstrate the capabilities of the method.

scholarly journals Numeric analysis of airflow around the body of the Silesian Greenpower vehicle

2018 ◽  
Vol 178 ◽  
pp. 05014 ◽  
Author(s):  
Andrzej Baier ◽  
Łukasz Grabowski ◽  
Łukasz Stebel ◽  
Mateusz Komander ◽  
Przemysław Konopka ◽  
...  
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Cfd Simulation ◽  
Simulation Software ◽  
The Body ◽  
Ansys Fluent ◽  
Electric Cars ◽  
Car Body ◽  
Race Car ◽  
Element Method

Numerical analysis of drag values of an electric race car's body. Silesian Greenpower is a student organization specializing in electric race car design. One of the most important issues during the design is reducing the vehicle drag to minimum and is done, mainly, by designing a streamline car body. The aim of this work was to design two electric cars bodies with different shape in Siemens NX CAD software, next a finite elements mesh was created and implemented into the ANSYS Workbench 16.1 software. Afterwards an aerodynamic analysis was carried out, using the finite element method (FEM). Simulations and calculations have been performed in ANSYS Fluent: CFD Simulation software. Computer simulation allowed to visualize the distribution of air pressure on and around car, the air velocity distribution around the car and aerodynamics streamline trajectory. The results of analysis were used to determine the drag values of electric car and determine points of the highest drag. In conclusion car body representing lower drag was appointed. The work includes theoretical introduction, containing information about finite element method, ANSYS and Siemens NX software and also basic aerodynamics laws.

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