Finite Element Analysis of Burr Formation in Micro-Machining

2014 ◽  
Vol 487 ◽  
pp. 225-229
Author(s):  
Juan Huang ◽  
Yong Hua Xiong ◽  
Jin Gui Huang ◽  
Gui Cheng Wang
Keyword(s):  
Finite Element ◽  
High Surface ◽  
Cutting Parameters ◽  
Burr Formation ◽  
Contact Friction ◽  
Tool Geometry ◽  
Work Piece ◽  
Micro Cutting ◽  
Finite Element Software ◽  
General Law

In the process of micro-cutting for the precision small parts, one of the main problems is the micro burrs. The finite element software Abaqus was used to simulate the micro-cutting process of aluminum 2024-T3. To create this model, Johnson-Cook (J-C) model was used to establish the material model, and Arbitrary Lagrangian Eulerian (ALE) method was used to separate the chip from work-piece. The contact friction models which was used between chip and tool was the modified Coulomb friction law. The formation process of micro burrs was simulated dynamically, and the effect of different cutting parameters and tool geometry parameters on burrs forming was analyzed. Furthermore, the general law was obtained. The results provide the guidance for optimizing the tool geometry parameters and cutting parameters to reduce the burrs in micro-cutting with the high surface quality.

scholarly journals Study on Burr Formation at the Top Edge in Rectangular Groove Cutting

2012 ◽  
Vol 2012 ◽  
pp. 1-9 ◽  
Author(s):  
Wen Jun Deng ◽  
Zi Chun Xie ◽  
Ping Lin ◽  
Tong Kui Xu
Keyword(s):  
Finite Element ◽  
Cutting Parameters ◽  
Burr Formation ◽  
Major Influence ◽  
Finite Element Software ◽  
Burr Size ◽  
Plastic Deformation Behavior ◽  
Cutting Operation ◽  
Rectangular Groove ◽  
Groove Cutting

Previous research on burr formation in machining operations has usually been limited to the study of the rollover burr in the cutting direction. In this paper, a 3D finite element model to simulate rectangular groove cutting operation has been developed using commercial finite element software, employing experimentally determined mechanical properties at elevated strain rates and temperatures. The plastic deformation behavior and three-dimensional burr formation during rectangular groove cutting is investigated. The simulated burr profile and cutting force prove that the developed model can capture the thermo-mechanical mechanisms in rectangular groove cutting and can simulate burr development with considerable accuracy. The study concentrates on the influence of cutting parameters on burr formation which are also conducted. The results show that the feed rate and rake angle are the cutting parameters which have a major influence on burr size in the groove cutting operation. And the effect of cutting velocity and minor clearance angle in the traditional range on burr size are quite limited.

Analysis on Temperature Field of Work-Piece during Cross Wedge Rolling

2011 ◽  
Vol 230-232 ◽  
pp. 352-356
Author(s):  
Wen Ke Liu ◽  
Kang Sheng Zhang ◽  
Zheng Huan Hu
Keyword(s):  
Finite Element ◽  
Temperature Field ◽  
Metal Flow ◽  
Work Piece ◽  
Contact Deformation ◽  
Cross Wedge Rolling ◽  
Forming Process ◽  
Rigid Plastic ◽  
Finite Element Software ◽  
Deform 3D

Based on the rigid-plastic deformation finite element method and the heat transfer theories, the forming process of cross wedge rolling was simulated with the finite element software DEFORM-3D. The temperature field of the rolled piece during the forming process was analyzed. The results show that the temperature gradient in the outer of the work-piece is sometimes very large and temperature near the contact deformation zone is the lowest while temperature near the center of the rolled-piece keeps relatively stable and even rises slightly. Research results provide a basis for further study on metal flow and accurate shaping of work-piece during cross wedge rolling.

scholarly journals Tool geometry analysis for plunge milling of lead-free CuZn-alloys

2021 ◽  
Author(s):  
Stefan Baier ◽  
Lukas Kokozinski ◽  
Daniel Schraknepper ◽  
Thomas Bergs
Keyword(s):  
Cutting Parameters ◽  
Lead Free ◽  
Tool Geometry ◽  
Work Piece ◽  
Plunge Milling ◽  
Process Step ◽  
Pilot Hole ◽  
Electrical Connector ◽  
Cutting Force Components ◽  
Force Components

Plunge milling is a critical process step in mass manufacturing of rectangular shapes in electrical connector components. These shapes are manufactured by drilling a pilot hole and subsequent plunge milling with a radial offset (pitch) one or more times. The plunged cavity serves as guidance for the final broaching cut. In light of new legislative initiatives, the electronics industry is forced to use lead-free Cu-Zn-Alloys for mass manufacturing of these connectors. The plunging tool is deflected due to the higher cutting forces experienced in machining of lead-free CuZn-alloys in comparison to alloys with lead. This results in an offset of the milled cavity and negatively impacts tool guidance in the subsequent broaching process. Therefore, the geometric tolerances cannot be met. In this paper, the effect of tool geometry and cutting parameters on the workpiece geometry in plunge milling is investigated. The effect of the microstructure of the work-piece materials CuZn37, CuZn42 and CuZn21Si3P on the tool deflection and cutting force components is examined. The tools used vary regarding the design of the corner in terms of the corner chamfer and the inner shaft thickness. Friction between chips in the tools inner flutes and the cavity walls reduced workpiece accuracy. Improvements were achieved by reducing the width of the cutting corner chamfers, using large inner flutes and applying low cutting parameters.

scholarly journals Finite Element Analysis and Statistical Optimization of End-Burr in Turning AA2024

Metals ◽  
2019 ◽  
Vol 9 (3) ◽  
pp. 276 ◽  
Author(s):  
Muhammad Asad ◽  
Hassan Ijaz ◽  
Waqas Saleem ◽  
Abdullah Mahfouz ◽  
Zeshan Ahmad ◽  
...  
Keyword(s):  
Finite Element ◽  
Orthogonal Cutting ◽  
Research Work ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Shear Zones ◽  
Statistical Analyses ◽  
Burr Formation ◽  
Pivot Point ◽  
Exit Edge

This contribution presents three-dimensional turning operation simulations exploiting the capabilities of finite element (FE) based software Abaqus/Explicit. Coupled temperature-displacement simulations for orthogonal cutting on an aerospace grade aluminum alloy AA2024-T351 with the conceived numerical model have been performed. Numerically computed results of cutting forces have been substantiated with the experimental data. Research work aims to contribute in comprehension of the end-burr formation process in orthogonal cutting. Multi-physical phenomena like crack propagation, evolution of shear zones (positive and negative), pivot-point appearance, thermal softening, etc., effecting burr formation for varying cutting parameters have been highlighted. Additionally, quantitative predictions of end burr lengths with foot type chip formation on the exit edge of the machined workpiece for various cutting parameters including cutting speed, feed rate, and tool rake angles have been made. Onwards, to investigate the influence of each cutting parameter on burr lengths and to find optimum values of cutting parameters statistical analyses using Taguchi’s design of experiment (DOE) technique and response surface methodology (RSM) have been performed. Investigations show that feed has a major impact, while cutting speed has the least impact in burr formation. Furthermore, it has been found that the early appearance of the pivot-point on the exit edge of the workpiece surface results in larger end-burr lengths. Results of statistical analyses have been successfully correlated with experimental findings in published literature.

Comparison between EBM and DMLS Ti6Al4V Machinability Characteristics under Dry Micro-Milling Conditions

2016 ◽  
Vol 836-837 ◽  
pp. 177-184 ◽  
Author(s):  
Zdenka Rysava ◽  
Stefania Bruschi
Keyword(s):  
Titanium Alloys ◽  
Surface Defects ◽  
Removal Rate ◽  
Cutting Speed ◽  
Micro Milling ◽  
Burr Formation ◽  
Tool Geometry ◽  
Work Piece ◽  
Dry Cutting ◽  
High Flexibility

This paper is aimed at evaluating the micro-machinability of the Ti-6Al-4V titanium alloy made by the means of two different Additive Manufacturing (AM) technologies. AM comprises promising technologies, widely used especially to produce parts made of difficult-to-cut materials, such as the titanium alloys. Titanium alloys represent one of the most widely used materials in the biomedical field, thanks to the high biocompatibility and excellent mechanical characteristics. Even if near-net-shape parts can be produced through AM, semi-finishing and/or finishing machining operations may be necessary to obtain the required surface finish and geometrical tolerances. Micro-milling technique is a soliciting solution for this kind of application due to its high flexibility, elevated material removal rate and direct contact between the tool geometry and work piece. Nevertheless, there are deficiencies in the literature regarding the study of micro-machinability of materials produced by means of AM technologies. In this paper, the micro-machinability of the Ti-6Al-4V alloy obtained by two different AM technologies, namely Electron Beam Melting (EBM) and Direct Metal Laser Sintering (DMLS), was studied and compared in order to assess the influence of the material as-delivered condition. Micro-milling tests were conducted on a high-precision 5-axis Kugler™ micro-milling centre under dry cutting conditions, by using uncoated, two fluted, flat-end-square, tungsten carbide tools with a diameter of 300 microns. The full immersion slotting strategy was chosen under full factorial design of experiments with two factors (cutting speed and feed per tooth). The micro-machinability was evaluated in terms of burr formation, surface integrity (surface topography and surface defects), tool damage and microstructure alterations.

Experimental Investigation on the Effect of Tool Geometry and Cutting Conditions Using Tool Wear Prediction Model for End Milling Process

2014 ◽  
Vol 13 (01) ◽  
pp. 41-54 ◽  
Author(s):  
S. Kalidass ◽  
P. Palanisamy
Keyword(s):  
Tool Wear ◽  
End Milling ◽  
Cutting Parameters ◽  
304 Stainless Steel ◽  
Tool Geometry ◽  
Depth Of Cut ◽  
Work Piece ◽  
Cutting Condition ◽  
Machining Parameter

Tool wear of a cutting tool has a significant impact on the tool life and surface quality of the finished product. Tool wear is influenced by many factors such as cutting parameters, tool geometry, coating type, work piece material, chatter, and cutting condition. In the present work, the design of experiments (DOE) technique has been used for four factors at five levels to conduct experiments. Tool wear is taken as the response variable measured during end milling, while helix angle, spindle speed, feed and depth of cut are taken as the input parameters. The material and tool selected for this study are AISI 304 stainless steel and uncoated solid carbide end mill cutter respectively. The tool wear was measured using tool maker's microscope. The experimental values are used in six sigma software for finding the coefficients to develop the regression model. The direct and interaction effect of the machining parameter with tool wear were analyzed using contour graphs, which helped to select process parameters for reducing tool wear and also ensure quality of milling.

Physical Simulation of Cutting Process and Optimization of Cutting Parameters

2012 ◽  
Vol 522 ◽  
pp. 210-216
Author(s):  
Tian Biao Yu ◽  
Xue Wei Zhang ◽  
Jia Ying Pei ◽  
Wan Shan Wang
Keyword(s):  
Finite Element ◽  
High Temperature ◽  
Cutting Force ◽  
Finite Element Simulation ◽  
Physical Simulation ◽  
Cutting Parameters ◽  
Cutting Process ◽  
Finite Element Software ◽  
Element Simulation ◽  
Optimization Of Cutting Parameters

Based on metal cutting theory and the key technology of finite element simulation, this paper uses finite element software Deform to establish three-dimensional finite element simulation model and simulate cutting process. This paper uses the work piece material is IN718 high temperature alloys packaged in Deform, and analyzes the processing characteristics of high temperature, choosing the right tools and cutting dosages to simulate. Through the simulation we can get scraps forming process, the surface stress, strain, temperature and cutting force distribution of the workpiece and the tool. We can also get the change rule of cutting force and cutting temperature under the different cutting parameters. The simulation results provide the theoretical basis for the optimization of cutting parameter selection in production practice.

Research on Temperature Field about Cutting Area in Plunge Milling Ti Alloy Based on Finite Element

2010 ◽  
Vol 102-104 ◽  
pp. 630-633
Author(s):  
Xu Da Qin ◽  
Wei Cheng Liu ◽  
Hao Jia ◽  
Xiao Lai Ji
Keyword(s):  
Thermal Conductivity ◽  
Finite Element ◽  
Temperature Field ◽  
Thermal Conductivity Coefficient ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Ti Alloy ◽  
Plunge Milling ◽  
Finite Element Software

Because of the small thermal conductivity coefficient of Ti alloy, the heat cannot disperse timely and accumulate seriously when plunge milling Ti alloy. If the cutting parameters can not be controlled well, the phenomenon of sticking will happen easily. According to the simulation and analysis of temperature field by using finite element software ABAQUS, the influence on cutting speed and feed for the Distributing of Temperature Field about Cutting Area in Plunge Milling Ti Alloy is acquired.

Finite Element Modeling of Burr Formation in Metal Cutting with a Backup Material

2007 ◽  
Vol 24-25 ◽  
pp. 71-76 ◽  
Author(s):  
Wen Jun Deng ◽  
Wei Xia ◽  
Long Sheng Lu ◽  
Yong Tang
Keyword(s):  
Finite Element ◽  
Finite Element Model ◽  
Material Properties ◽  
Metal Cutting ◽  
Element Model ◽  
Burr Formation ◽  
Tool Geometry ◽  
Cutting Condition ◽  
Burr Size ◽  
Initiation And Propagation

2D finite element model with the same material for backup to minimize the burr size was developed to investigate mechanism of burr formation and burr minimization. The flowstress of the workpiece and backup material are taken as a function of strain, strain-rate and temperature. Temperature-dependent material properties are also considered. The Cockroft-Latham damage criterion has been adopted to simulate ductile fracture. The crack initiation and propagation is simulated by deleting the mesh element. The result shows putting a backup material behind the edge of the workpiece is an effective way to minimize the burr size. The effects of cutting condition, temperature and different backup material properties on the burr formation and burr size can be investigated using the developed finite element model. This model could be useful in the search for optimal tool geometry and cutting condition for burr minimization and for the modeling of a burr formation mechanism.

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