Effect of Machining Parameters on Deformation Field in Machining by Finite Element Method

2011 ◽  
Vol 80-81 ◽  
pp. 942-945
Author(s):  
C.L. Wu ◽  
Z.R. Wang
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Cutting Force ◽  
Large Strain ◽  
Effective Strain ◽  
High Hardness ◽  
Rake Angle ◽  
Machining Parameters ◽  
Cutting Velocity ◽  
Element Method

Formation of chip is a typical severe plastic deformation progress in machining which is only single deformation stage. The large strain, low temperature and deformation force are the major premises to create significant microstructure refinement in metals and alloys. A finite element method was developed to characterize the distribution of strain, temperature and cutting force. Effects of rake angle, cutting velocity and friction on effective strain, cutting force imposed in the chip are researched and the conditions which lead to the large stain deformation in machining are highlighted. The results of simulation have shown that chip materials with ultrafine grained and high hardness can be produced with negative tool rake angle at some lower cutting velocity.

Research of Formation Mechanics on Nanostructured Chips by Multi-Deformations Based on Finite Element Method

2014 ◽  
Vol 989-994 ◽  
pp. 352-355
Author(s):  
C.L. Wu ◽  
Z.R. Wang ◽  
Wen Zhang
Keyword(s):  
Finite Element Method ◽  
Plastic Deformation ◽  
Finite Element ◽  
Large Strain ◽  
Effective Strain ◽  
Longitudinal Section ◽  
Rake Angle ◽  
Governing Parameter ◽  
Cutting Velocity ◽  
Mean Strain

Formation of chip is a typical severe plastic deformation progress in machining which is only single deformation stage. The rake angle of tool is governing parameter to create large strain imposed in the chip. Effect of rake angle and deformation times on effective strain, mean strain, strain variety and strain rate imposed in the chip are researched respectively. The result of simulation have shown that the chip with large strain and better uniform of strain along the longitudinal section of chip can be produced with negative rake angle at some lower cutting velocity by multi-deformations in large strain machining.

Deformation Characteristics of Ultra-Fine Grained Al6061 Chip in Machining by Finite Element Method

2010 ◽  
Vol 44-47 ◽  
pp. 2931-2934
Author(s):  
Chun Ling Wu ◽  
Bang Yan Ye
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Coefficient Of Friction ◽  
Metal Cutting ◽  
High Hardness ◽  
Rake Angle ◽  
Fine Grained ◽  
The Coefficient Of Friction ◽  
Cutting Velocity ◽  
Element Method

Ultra-fine grained chips with higher hardness and strength than bulk can be produced by severe plastic deformation during orthogonal metal cutting. A finite element method was developed to characterize the distribution of stress, strain, strain rate and temperature in the deformation area at different rake angles and cutting velocities. The coefficient of friction in the tool-chip interface is approximately obtained according model of mean coefficient of friction which is based on experiments in any machining conditions. The formation mechanics of ultra-fine grained chip is discussed and effect of rake angle on microstructure of chips is highlighted. The results of experiment and modeling have shown that chip materials with ultra-fine grained and high hardness can be produced with more negative tool rake angle at some lower cutting velocity.

Effect of Machining Parameters on Microstructure and Hardness of Ultra-Fine Grained Material Created by Large Strain Machining

2009 ◽  
Vol 628-629 ◽  
pp. 387-392 ◽  
Author(s):  
Chun Ling Wu ◽  
Bang Yan Ye ◽  
Wen Jun Deng
Keyword(s):  
Large Strain ◽  
High Hardness ◽  
Shear Plane ◽  
Rake Angle ◽  
Machining Parameters ◽  
Fine Grained ◽  
Hardness Tester ◽  
Fine Grain ◽  
Cutting Velocity ◽  
Fine Grained Material

Effect of plane strain machining parameters such as rake angle and cutting velocity on the formation of ultra-fine structure in several materials has been studied. The microstructure and hardness of chips generated by machining were characterized by optical microscopy, scan electron microscopy and hardness tester respectively. The experimental results indicated that chip materials with ultra-fine grained and high hardness can be produced with more negative tool rake angle at some lower cutting velocity. The rake angle has more important effect on the formation of ultra-fine grain chips than cutting velocity. The rake angle for getting chips of obvious refined and significant hardened is different for different materials respectively. While the temperature of shear plane and tool-chip interface are increased with the increasing cutting velocity which alleviates the increase of hardness produced by decreasing rake angle.

scholarly journals Cutting Force Predication Based on Integration of Symmetric Fuzzy Number and Finite Element Method

2014 ◽  
Vol 2014 ◽  
pp. 1-8 ◽  
Author(s):  
Zhanli Wang ◽  
Yanjuan Hu ◽  
Yao Wang ◽  
Chao Dong ◽  
Zaixiang Pang
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Cutting Force ◽  
Fuzzy Number ◽  
Experimental Result ◽  
The Finite Element Method ◽  
Mechanical Coupling ◽  
Fuzzy Function ◽  
Nonuniform Stress Field ◽  
Element Method

In the process of turning, pointing at the uncertain phenomenon of cutting which is caused by the disturbance of random factors, for determining the uncertain scope of cutting force, the integrated symmetric fuzzy number and the finite element method (FEM) are used in the prediction of cutting force. The method used symmetric fuzzy number to establish fuzzy function between cutting force and three factors and obtained the uncertain interval of cutting force by linear programming. At the same time, the change curve of cutting force with time was directly simulated by using thermal-mechanical coupling FEM; also the nonuniform stress field and temperature distribution of workpiece, tool, and chip under the action of thermal-mechanical coupling were simulated. The experimental result shows that the method is effective for the uncertain prediction of cutting force.

Modeling and Simulation of High Speed Intermittent Cutting Based on the Finite Element Method

2013 ◽  
Vol 683 ◽  
pp. 556-559
Author(s):  
Bin Bin Jiao ◽  
Fu Sheng Yu ◽  
Yun Jiang Li ◽  
Rong Lu Zhang ◽  
Gui Lin Du ◽  
...  
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Stress Field ◽  
Cutting Force ◽  
High Speed ◽  
Element Model ◽  
Periodic Variation ◽  
Element Analysis ◽  
Intermittent Cutting ◽  
Element Method

In order to study the distribution of the stress field in the high-speed intermittent cutting process, finite element model of high-speed intermittent cutting is established. Exponential material model of the constitutive equation and adaptive grid technology are applied in the finite element analysis software AdvantEdge. The material processing is simulated under certain cutting conditions with FEM ( Finite Element Method ) and the distribution of cutting force, stress field, and temperature field are received. A periodic variation to the cutting force and temperature is showed in the simulation of high-speed intermittent cutting. Highest value of the milling temperature appears in front contacting area of the knife -the chip.and maximum stress occurs at the tip of tool or the vicinity of the main cutting edge. The analysis of stress and strain fields in-depth is of great significance to improve tool design and durability of tool.

Deformation Mechanics Associated with Formation of Ultra-Fine Grained Chips in Machining

2006 ◽  
Vol 503-504 ◽  
pp. 379-384 ◽  
Author(s):  
Michael Sevier ◽  
Seongeyl Lee ◽  
M. Ravi Shankar ◽  
Henry T.Y. Yang ◽  
Srinivasan Chandrasekar ◽  
...  
Keyword(s):  
Large Strain ◽  
Rake Angle ◽  
Image Sequences ◽  
Deformation Field ◽  
Machining Parameters ◽  
The Finite Element Method ◽  
Fine Grained ◽  
Image Velocimetry ◽  
Cutting Velocity ◽  
Deformation Mechanics

The deformation field associated with chip formation in plane strain (2-D) machining has been simulated using the finite element method (FEM), with the objective of developing 2-D machining as an experimental technique for studying very large strain deformation phenomena. The principal machining parameters are the tool rake angle, cutting velocity and the friction at the toolchip interface while the deformation field parameters are strain, strain rate and temperature. The relation between rake angle and the shear strain in the deformation zone is studied for the low-speed cutting of lead. This correspondence is validated by comparison with measurements of the deformation parameters made by applying a Particle Image Velocimetry (PIV) technique to highspeed photographic image sequences of the deformation. It is shown that plastic strains in the range of 1-15 can be realized in a controlled manner by appropriate choice of the rake angle. The unique capabilities offered by 2-D machining for studying micro- and nano- mechanics of large strain deformation, and the creation of ultra-fine grained materials are highlighted in the context of these results.

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