Finite Element Modeling for High Speed Machining of Ti-6Al-4V Using ALE Boundary Technology

2011 ◽  
Vol 66-68 ◽  
pp. 1509-1514
Author(s):  
Dong Lu ◽  
Ming Ming Yang ◽  
Hong Fu Huang ◽  
Xiao Hong Zhong
Keyword(s):  
Finite Element ◽  
Finite Element Model ◽  
High Speed ◽  
Element Model ◽  
Machining Process ◽  
Computational Time ◽  
High Speed Machining ◽  
Tool Edge Radius ◽  
Edge Radius ◽  
Tool Edge

A finite element model of HSM (High Speed Machining) process of Ti6Al4V was developed with Abaqus 6.10. The flow stress of Ti6Al4V is taken as a function of strain, strain rate and temperature. Considering the fact that the tool edge radius is relatively large in HSM of Ti6Al4V and significantly influences the mechanical behaviour, thus a new Arbitrary Lagrangian-Eulerian (ALE) boundary technology was incorporated into the finite element model to simulate the flowing material around the tool edge.The adoption of ALE boundary technology could avoid using the traditional chip separation criterias and element deletion method in the model, which at the same time results in the less excessive element distortion and computational time in comparison with traditional finite element models of cutting process. The simulation results of Cutting force and temperature close to the experimental values in an acceptable range could be obtained and a stagnant zone in front of the tool edge was successfully observed in this new developed model with large tool edge radius.

Implementation of Advanced Frictional Laws for Modelling of High Speed Machining

2013 ◽  
Vol 554-557 ◽  
pp. 2021-2028
Author(s):  
Yannick Senecaut ◽  
Michel Watremez ◽  
Damien Meresse ◽  
Laurent Dubar
Keyword(s):  
Finite Element ◽  
Finite Element Model ◽  
High Speed ◽  
Orthogonal Cutting ◽  
Element Model ◽  
Machining Process ◽  
Experimental Device ◽  
High Speed Machining ◽  
Input Parameters ◽  
Numerical Approaches

High-speed machining is submitted to economical and ecological constraints. Optimization of cutting processes must increase productivity, reduce tool wear and control residual stresses in the workpiece. Developments of numerical approaches to simulate accurately high-speed machining process are therefore necessary since in situ optimization is long and costly. To get this purpose, rheological behaviour of both antagonists and representative friction models at tool-chip interface has to be studied as encountered during high-speed machining process. The study is led with AISI 1045 steel and an uncoated carbide tool. An experimental device has been first designed to simulate the friction behaviour at the tool-chip interface only in the zone near the cutting edge. Several tests are then performed to provide experimental data and these data are used to define the friction coefficient versus to the contact pressure, the sliding velocity and the interfacial temperature by a new formulation frictional law given by Brocail et al (2010). A two-dimensional finite element model of orthogonal cutting is developed with Abaqus/explicit software. An Arbitrary Lagrangian-Eulerian (ALE) formulation is used to predict chip formation, temperature, chip-tool contact length, chip thickness, and cutting forces. This numerical model of orthogonal cutting is then validated by comparing these process variables to experimental and numerical results obtained by Filice et al. (2006). This model makes possible qualitative analysis of input parameters related to cutting process and frictional models. A sensitivity analysis has been performed on the main input parameters (coefficients of the Johnson-Cook law, contact and thermal parameters) with the finite element model. The interfacial law determined by Brocail et al (2010) is implemented on this finite element model of machining and leads to improve numerical approaches of machining. Nevertheless, even if this law enables to reduce results between experimental and numerical approaches, some differences are still substantial. The advanced friction law must be complemented for higher sliding velocities and this work using a new specific experimental device will be presented in the second part of this paper.

Modal Analysis of BT Spindle-Toolholder Interface Based on Abaqus/Standard

2013 ◽  
Vol 662 ◽  
pp. 632-636
Author(s):  
Yong Sheng Zhao ◽  
Jing Yang ◽  
Xiao Lei Song ◽  
Zi Jun Qi
Keyword(s):  
Finite Element ◽  
Finite Element Model ◽  
Modal Analysis ◽  
Dynamic Characteristics ◽  
High Speed ◽  
Element Model ◽  
Contact Theory ◽  
High Speed Machining ◽  
The Finite Element Model

The quality of high speed machining is directly related to dynamic characteristics of spindle-toolholder interface. The paper established normal and tangential interactions of BT spindle-toolholder interface based on finite element contact theory, and analysed free modal in Abaqus/Standard. Then the result was compared with the experimental modal analysis. It shows that the finite element model is effective and could be applied in the future dynamic study of high-speed spindle system.

Study on the Influence of Different Tool Edge Radius on Milling Ti6Al4V

2010 ◽  
Author(s):  
Yueping Liu ◽  
Jianfeng Li ◽  
Jie Sun ◽  
Feng Jiang
Keyword(s):  
Finite Element ◽  
Finite Element Model ◽  
Tool Life ◽  
Chip Morphology ◽  
Element Model ◽  
Fem Model ◽  
Edge Radius ◽  
Cutting Heat ◽  
Tool Edge ◽  
Edge Preparation

Short tool life is one of the bottleneck problems in Ti6Al4V machining. Edge preparation plays an important role on tool life. To investigate the influence of edge preparation on cutting force, cutting heat and chip morphology et al, Finite element model (FEM) is established. The software adopted in this study is ThirdWaveSystems AdvantEdge. Experiment is designed to verify the validation of the FEM model. Based on the validated FEM, optimized edge radius is obtained.

Finite Element Analysis of Micro-Cutting Aluminum 7050-T7451 with the Tool Edge Radius Considered

2010 ◽  
Vol 443 ◽  
pp. 663-668 ◽  
Author(s):  
Jun Zhou ◽  
Jian Feng Li ◽  
Jie Sun
Keyword(s):  
Finite Element ◽  
Plastic Strain ◽  
Cutting Temperature ◽  
Machining Process ◽  
Micro Machining ◽  
Element Analysis ◽  
Micro Cutting ◽  
Tool Edge Radius ◽  
Edge Radius ◽  
Tool Edge

In this paper, a series of simulation works by finite element method for predicting the temperature and the plastic strain distributions in micro cutting process with the tool edge radius considered were conducted. The workpiece is Aluminum alloy 7050-T7451 and its flow stress is taken as a function of strain, strain rate and temperature in order to reflect realistic behavior in machining process. From the simulation works, a lot of information on the micro-machining process can be obtained, such as cutting force, cutting temperature, distributions of temperature and plastic strain, etc. In addition, explanations for the observed trends are also given.

Simulation and Experimental Research on Milling Force of High Manganese Steel

2010 ◽  
Vol 143-144 ◽  
pp. 863-867
Author(s):  
Yong Tang ◽  
Qiang Wu ◽  
Xiao Fang Hu ◽  
Yu Zhong Li
Keyword(s):  
Finite Element ◽  
Finite Element Model ◽  
High Speed ◽  
Shear Failure ◽  
Element Model ◽  
Manganese Steel ◽  
High Manganese ◽  
Milling Force ◽  
High Manganese Steel ◽  
High Speed Milling

The milling process of hard-to-cut material high manganese steel ZGMn13 was simulated and experimental studied based on Johnson-Cook material model and shear failure model.The high speed milling processing finite element model has established adopting arbitrary Lagrangian-Euler method (ALE) and the grid adaptive technology,The influence of milling parameters to milling force is analyzed in the high speed milling high manganese steel process. The simulated and experimental results being discussed are matched well. It certifies the finite element model is correct.

Validation of a New Finite Element Model for Human Knee Ligaments for Use in High Speed Automotive Collisions

2009 ◽  
Author(s):  
Chiara Silvestri ◽  
Louis R. Peck ◽  
Kristen L. Billiar ◽  
Malcolm H. Ray
Keyword(s):  
Finite Element ◽  
Finite Element Model ◽  
Strain Rate ◽  
High Speed ◽  
Element Model ◽  
Knee Ligament ◽  
Knee Ligaments ◽  
Human Knee ◽  
Dynamic Representation ◽  
Failure Properties

A finite element model of knee human ligaments was developed and validated to predict the injury potential of occupants in high speed frontal automotive collisions. Dynamic failure properties of ligaments were modeled to facilitate the development of more realistic dynamic representation of the human lower extremities when subjected to a high strain rate. Uniaxial impulsive impact loads were applied to porcine medial collateral ligament-bone complex with strain rates up to145 s−1. From test results, the failure load was found to depend on ligament geometric parameters and on the strain rate applied. The information obtained was then integrated into a finite element model of the knee ligaments with the potential to be used also for representation of ligaments in other regions of the human body. The model was then validated against knee ligament dynamic tolerance tests found in literature. Results obtained from finite element simulations during the validation process agreed with the outcomes reported by literature findings encouraging the use of this ligament model as a powerful and innovative tool to estimate ligament human response in high speed frontal automotive collisions.

Sign in / Sign up

Export Citation Format

Share Document