Finite Element Technique for Predicting Stress Distribution in Milling TC4 Titanium Alloy

2014 ◽  
Vol 623 ◽  
pp. 121-124
Author(s):  
Bin Li ◽  
Shu Ling Zhao
Keyword(s):  
Finite Element ◽  
Titanium Alloy ◽  
Material Flow ◽  
Cutting Speed ◽  
Milling Process ◽  
Machining Process ◽  
Engineering Technology ◽  
Tc4 Titanium Alloy ◽  
Metal Machining ◽  
Element Technique

Cutting forces modeling is the basis to understand, simulate milling process and further to control milling process parameters for obtaining higher precision workpieces. With the development of engineering technology, FEM can be used to simulate metal machining process and gain better understanding of material flow within dies, so as to optimize tooling to eliminate tears, laps and other forging defects. In this paper, the calculated cutting force increases approximately logarithmically with the cutting speed, as should be expected from the logarithmic rate dependence.

An Analytical Finite Element Technique for Predicting Temperature Distribution in Turning Titanium Alloy

2012 ◽  
Vol 184-185 ◽  
pp. 886-889
Author(s):  
Bin Li ◽  
Hong Wang
Keyword(s):  
Material Flow ◽  
Flow Behavior ◽  
Metal Flow ◽  
Cutting Temperature ◽  
Machining Process ◽  
Engineering Technology ◽  
Metal Machining ◽  
Tc4 Alloy ◽  
Simulation Results ◽  
Element Technique

With the development of engineering technology, FEM can be used to simulate metal machining process and gain better understanding of material flow within dies, so as to optimize tooling to eliminate tears, laps and other forging defects. In this paper, numerical simulation was conducted by using FEM software on the whole cutting process for TC4 alloy mounting parts in an effort to investigate the metal flow behavior. The thermal simulation results obtained were compared with the cutting temperature and discussed in terms of literature data.

Numerical Simulation and Prediction of Cutting Force in Turning of Titanium Alloy

2012 ◽  
Vol 580 ◽  
pp. 63-66 ◽  
Author(s):  
Bin Li ◽  
Hong Wang
Keyword(s):  
Numerical Simulation ◽  
Cutting Force ◽  
Material Flow ◽  
Flow Behavior ◽  
Metal Flow ◽  
Cutting Speed ◽  
Machining Process ◽  
Engineering Technology ◽  
Metal Machining ◽  
Tc4 Alloy

Though titanium alloys are being increasingly sought in a wide variety of engineering and biomedical applications, their manufacturability, especially machining and grinding imposes lot of constraints. With the development of engineering technology, FEM can be used to simulate metal machining process and gain better understanding of material flow within dies, so as to optimize tooling to eliminate tears, laps and other forging defects. In this paper, numerical simulation was conducted by using FEM software on the whole cutting process for TC4 alloy mounting parts in an effort to investigate the metal flow behavior. The calculated cutting force increases approximately logarithmically with the cutting speed, as should be expected from the logarithmic rate dependence.

Cutting forces analysis of micro-milling process on Inconel 718 – a finite element approach

2020 ◽  
Vol 11 (02) ◽  
pp. 2050011
Author(s):  
Padmaja Tripathy ◽  
Kalipada Maity
Keyword(s):  
Finite Element ◽  
Cutting Forces ◽  
Inconel 718 ◽  
Cutting Speed ◽  
Fem Analysis ◽  
Milling Process ◽  
Machining Process ◽  
Micro Milling ◽  
Depth Of Cut ◽  
Machining Parameters

This paper presents a modeling and simulation of micro-milling process with finite element modeling (FEM) analysis to predict cutting forces. The micro-milling of Inconel 718 is conducted using high-speed steel (HSS) micro-end mill cutter of 1mm diameter. The machining parameters considered for simulation are feed rate, cutting speed and depth of cut which are varied at three levels. The FEM analysis of machining process is divided into three parts, i.e., pre-processer, simulation and post-processor. In pre-processor, the input data are provided for simulation. The machining process is further simulated with the pre-processor data. For data extraction and viewing the simulated results, post-processor is used. A set of experiments are conducted for validation of simulated process. The simulated and experimental results are compared and the results are found to be having a good agreement.

A Finite Element Analysis for the Characteristics of Cutting Parameters in 3D Oblique Milling Process

2010 ◽  
Vol 97-101 ◽  
pp. 3010-3013
Author(s):  
Guo Hua Qin ◽  
S.Q. Xin ◽  
Dong Lu ◽  
Yi Ming Rong
Keyword(s):  
Finite Element ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Element Model ◽  
Milling Process ◽  
Machining Process ◽  
Element Analysis ◽  
Complete Procedure ◽  
Commercial Software Package ◽  
Chip Removal

In the field of aeronautical and astronautical manufacturing, milling is a basic machining process by which a surface is generated by progressive chip removal. Therefore, this paper reports a complete procedure of the finite element model for the 3D oblique milling process using the commercial software package ABAQUS. Effect of various parameters on cutting forces is mainly discussed. The model correctly exhibits the observed transition from small to large force with increasing cutting speed and cutting depth.

Machinability of ZTC4 Titanium Alloy Analysis Using Finite Element Simulation and Milling Experiment

2011 ◽  
Vol 474-476 ◽  
pp. 633-638 ◽  
Author(s):  
Chang Yi Liu ◽  
Zhi An Tang ◽  
Sheng Yang ◽  
Wen Wen Liu ◽  
Yuan Dong Lu
Keyword(s):  
Finite Element ◽  
Titanium Alloy ◽  
Fem Simulation ◽  
Milling Process ◽  
Machining Process ◽  
Three Dimension ◽  
3D Fem ◽  
Chip Flow ◽  
Clearance Face ◽  
Elastic And Plastic Deformation

In this paper Finite element methods (FEM) and cutting experiment were used to investigate the machinability of titanium alloy ZTC4 (cast Ti6Al4V). Machinability was evaluated as cutting force, temperature, and surface roughness. Two-dimension (2D) and three-dimension (3D) machining process FEM models were established. Material constitutive applied Johnson-Cook model synthesizing elastic and plastic deformation. Chip separated criteria adopted arbitrary Lagrangian Euler (ALE) algorithm. Heat generation source included the rake face chip flow under conditions of seizure and chip/tool friction, clearance face tool/workpiece friction. 3D discrete milling tool was modeled and the milling process was simulated. The ZTC4 milling experiments were designed and carried out with same cutting conditions of the 3D FEM simulation. The results of FEM simulation and the experiment were compared and analysed. The influences of the machining variables to the machinability of ZTC4 were discussed.

Mechanism of Variable Helix Tools in Suppressing Chatter Using Process Damping for Machining Titanium Alloys at Low Cutting Speed

2013 ◽  
Vol 773-774 ◽  
pp. 370-376
Author(s):  
Muhammad Adib Shaharun ◽  
Ahmad Razlan Yusoff ◽  
Mohammad S. Reza
Keyword(s):  
Titanium Alloy ◽  
Cutting Speed ◽  
Milling Process ◽  
Cutting Process ◽  
Chatter Vibration ◽  
Process Damping ◽  
High Cutting Speed ◽  
Titanium Machining ◽  
Different Types ◽  
Variable Helix

Titanium is difficult-to-cut materials due to its poor machinability and thermal conductivity when machining at high cutting speed. To overcome this machining titanium alloy problem, this study in interaction between machining structural system and the cutting process are very important. One of the main problems in the cutting process is chatter vibration. Due to chatter problem, the mechanism to suppress chatter named, process damping is a useful method can be manipulated to improve the limited productivity of titanium machining at low speed machining in milling process. In the present study, experiment are conducted to evaluate and study the process damping mechanism in milling using different types of variable tools geometries. These tools are variable he-lix/uniform pitch, variable pitch/uniform helix and variable helix and pitch and uniform helix/pitch. The result showed that the variable helix and pitch tools is very significantly improve process damping performance in machining titanium alloy compare to traditional of regular tools and other irregular tools.

scholarly journals Influence of Elastomer Layers in the Quality of Aluminum Parts on Finishing Operations

Metals ◽  
2020 ◽  
Vol 10 (2) ◽  
pp. 289 ◽  
Author(s):  
Antonio Rubio-Mateos ◽  
Asuncion Rivero ◽  
Eneko Ukar ◽  
Aitzol Lamikiz
Keyword(s):  
Process Parameters ◽  
Feed Rate ◽  
Cutting Speed ◽  
Milling Process ◽  
Machining Process ◽  
Butadiene Rubber ◽  
Compression Tests ◽  
Compressive Behavior ◽  
Finishing Processes

In finishing processes, the quality of aluminum parts is mostly influenced by static and dynamic phenomena. Different solutions have been studied toward a stable milling process attainment. However, the improvements obtained with the tuning of process parameters are limited by the system stiffness and external dampers devices interfere with the machining process. To deal with this challenge, this work analyzes the suitability of elastomer layers as passive damping elements directly located under the part to be machined. Thus, exploiting the sealing properties of nitrile butadiene rubber (NBR), a suitable flexible vacuum fixture is developed, enabling a proper implementation in the manufacturing process. Two different compounds are characterized under axial compression and under finishing operations. The compression tests present the effect of the feed rate and the strain accumulative effect in the fixture compressive behavior. Despite the higher strain variability of the softer rubber, different milling process parameters, such as the tool feed rate, can lead to a similar compressive behavior of the fixture regardless the elastomer hardness. On the other hand, the characterization of these flexible fixtures is completed over AA2024 floor milling of rigid parts and compared with the use of a rigid part clamping. These results show that, as the cutting speed and the feed rate increases, due to the strain evolution of the rubber, the part quality obtained tend to equalize between the flexible and the rigid clamping of the workpiece. Due to the versatility of the NBR for clamping different part geometries without new fixture redesigns, this leads to a competitive advantage of these flexible solutions against the classic rigid vacuum fixtures. Finally, a model to predict the grooving forces with a bull-nose end mill regardless of the stiffness of the part support is proposed and validated for the working range.

Study on the improvement of the surface integrity and efficiency of electrical-discharge-machined TC4 titanium alloy via abrasive flow machining

2020 ◽  
pp. 095440542097109
Author(s):  
Ze Yu ◽  
Dunwen Zuo ◽  
Yuli Sun ◽  
Guohua Li ◽  
Xuemei Chen ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Titanium Alloy ◽  
Surface Quality ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Small Hole ◽  
Machining Process ◽  
Machining Efficiency ◽  
Abrasive Flow Machining ◽  
Tc4 Titanium Alloy

To simultaneously optimize the surface quality and machining efficiency of the electrical discharge machining (EDM) processes used to produce titanium alloy quadrilateral group small hole parts, a combined “EDM + AFM” machining technology is proposed in this paper as an efficient and high-quality machining approach. In the proposed method, TC4 titanium alloy is first machined using the EDM process with graphite electrodes and the abrasive flow machining (AFM) process is then used to finish the machined surface. The effects of various electrical parameters on EDM-derived surface quality and improvements in EDM-derived quality under the application of AFM were assessed and, using the final surface roughness as a constraint condition, the effects of various combinations of EDM and “EDM + AFM” on efficiency were studied. The results revealed that the thickness and surface roughness of the superficial recast layer of the TC4 titanium alloy increase with both current and pulse width; in particular, increasing these parameters can increase the surface roughness by two to three grades. Following AFM, the alloy has a more uniform hardness distribution and the surface stress state changes from tensile to compressive stress, indicating that the combined “EDM + AFM” machining scheme can significantly enhance the surface quality of EDM-produced titanium alloy quadrilateral small group holes. The combined scheme achieves a balancing point beyond which increasing the roughness or the number of machining holes enhances either the machining efficiency or the machining surface quality. In the case of typical titanium alloy quadrilateral group small hole parts, the combined machining process can improve the finishing efficiency and total machining efficiency by 71.2% and 25.36%, respectively.

Finite Element Simulation and Experimental Research on Micro-Milling Process of Titanium Alloy

2012 ◽  
Vol 522 ◽  
pp. 245-248 ◽  
Author(s):  
Hai Tao Liu ◽  
Ya Zhou Sun ◽  
De Bin Shan ◽  
Yan Quan Geng
Keyword(s):  
Finite Element ◽  
Titanium Alloy ◽  
Finite Element Simulation ◽  
Large Scale ◽  
Simulation Analysis ◽  
Cutting Speed ◽  
Micro Milling ◽  
Element Analysis ◽  
Element Simulation ◽  
Cutting Heat

There are lots of titanium alloy parts which have large-scale micro-structures in astronautic structure and medical implants, so the micro milling becomes one of the effective processing methods in getting the surface micro-structure. Because the titanium alloy has high caking property in processing, it needs a research on the cutting heat and force in order to get better machining precision and surface quality. According to the finite element theory in elastic and plasticity, the influence of cutting speed to the cutting heat and force is got by finite element simulation analysis to the titanium material TC4 in cutting process. It can get the simulation results of cutting heat and force in the micro milling processing by finite element analysis, and then compared, the basic influence which the cutting speed to the cutting heat and force is got. The correctness of the result is checked through cutting experiments.

Sign in / Sign up

Export Citation Format

Share Document