Finite Element Analysis of the Effect of Cutting Speed on the Orthogonal Turning of A359/SiCp MMC

2016 ◽  
Vol 852 ◽  
pp. 304-310
Author(s):  
M.M. Thamizharasan ◽  
Y.J. Nithiya Sandhiya ◽  
K.S. Vijay Sekar ◽  
V.V. Bhanu Prasad
Keyword(s):  
Finite Element ◽  
Matrix Material ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Fe Model ◽  
Element Analysis ◽  
Damage And Fracture ◽  
Orthogonal Turning ◽  
The Matrix ◽  
Cutting Speeds

The application of Metal Matrix Composite (MMC) has been increasing due to its superior strength and wear characteristics but the major challenge is its poor machinability due to the presence of reinforcement in the matrix which is a hindrance during machining. The material behaviour during machining varies with respect to input variables. In this paper the effect of cutting speed during the orthogonal turning of A359/SiCp MMC with TiAlN tool insert is analysed by developing a 2D Finite Element (FE) model in Abaqus FEA code. The FE model is based on plane strain formulation and the element type used is coupled temperature displacement. The matrix material is modeled using Johnson–Cook (J-C) thermal elastic–plastic constitutive equation and chip separation is simulated using Johnson–Cook’s model for progressive damage and fracture with parting line. Particle material is considered to be perfectly elastic until brittle fracture. The tool is considered to be rigid. The FE model analyses the tool interaction with the MMC and its subsequent effects on cutting forces for different cutting speeds and feed rates. The chip formation and stress distribution are also studied. The FE results are validated with the experimental results at cutting speeds ranging from 72 – 188 m/min and feed rates ranging from 0.111 – 0.446 mm/rev at constant depth of cut of 0.5mm.

Modified Anisotropic Gurson Yield Criterion for Porous Ductile Sheet Metals

2000 ◽  
Vol 123 (4) ◽  
pp. 409-416 ◽  
Author(s):  
W. Y. Chien ◽  
J. Pan ◽  
S. C. Tang
Keyword(s):  
Finite Element ◽  
Closed Form ◽  
Yield Criterion ◽  
Plastic Anisotropy ◽  
Matrix Material ◽  
Plastic Behavior ◽  
Computational Results ◽  
Sheet Metals ◽  
Element Analysis ◽  
The Matrix

The influence of plastic anisotropy on the plastic behavior of porous ductile materials is investigated by a three-dimensional finite element analysis. A unit cell of cube containing a spherical void is modeled. The Hill quadratic anisotropic yield criterion is used to describe the matrix normal anisotropy and planar isotropy. The matrix material is first assumed to be elastic perfectly plastic. Macroscopically uniform displacements are applied to the faces of the cube. The finite element computational results are compared with those based on the closed-form anisotropic Gurson yield criterion suggested in Liao et al. 1997, “Approximate Yield Criteria for Anisotropic Porous Ductile Sheet Metals,” Mech. Mater., pp. 213–226. Three fitting parameters are suggested for the closed-form yield criterion to fit the results based on the modified yield criterion to those of finite element computations. When the strain hardening of the matrix is considered, the computational results of the macroscopic stress-strain behavior are in agreement with those based on the modified anisotropic Gurson’s yield criterion under uniaxial and equal biaxial tensile loading conditions.

scholarly journals FEM-based comparative study of SQUARE & RHOMBIC INSERT machining performance during turning of AISI-D3 steel

2021 ◽  
Vol 13 (2) ◽  
pp. 143-148
Author(s):  
Anastasios Tzotzis ◽  
◽  
Nikolaos Efkolidis ◽  
Gheorghe Oancea ◽  
Panagiotis Kyratsis ◽  
...  
Keyword(s):  
Finite Element ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
The Finite Element Method ◽  
Machining Simulation ◽  
Machining Performance ◽  
Machining Processes ◽  
Element Analysis ◽  
Friction Forces ◽  
Aisi D3 Steel

Nowadays, employment of the Finite Element Method (FEM) in machining simulation is a common practice to decrease development times and costs, as well as to investigate numerous parameters that affect machining processes. In the present work, the 3D modelling of AISI-D3 hard turning with both square and rhombic inserts is being presented by utilizing a commercially available Finite Element Analysis (FEA) software. Eighteen tests were carried out based on cutting conditions that are recommended for the used tools. Specifically, three levels of cutting speed (75m/min, 110m/min and 140m/min), three levels of feed (0.12mm/rev, 0.16mm/rev and 0.20mm/rev) and depth of cut equal to 0.40mm for all tests, were applied. In order to describe the complex factors that define the model, such as the friction forces, the heat transfer and the pressure due to contact between the tool and the workpiece, a number of acknowledged models were utilized. A comparison of the performance between the two types of tools was made with respect to the developed machining forces and temperature distribution on the workpiece. The findings of the investigation indicate that the specific square tools produce higher values of forces compared to the rhombic ones and approximately the same temperature patterns on the workpiece. The average increase on the produced cutting forces is about 26.4%.

Finite Element Modeling for Prediction of Stress – Strain at Several Feed Rates and Cutting Speeds for Titanium (Ti-6Al-4V) Alloy

2012 ◽  
Vol 587 ◽  
pp. 11-15
Author(s):  
Moaz H. Ali ◽  
Basim A. Khidhir ◽  
Bashir Mohamed
Keyword(s):  
Finite Element ◽  
Orthogonal Cutting ◽  
Cutting Speed ◽  
Equivalent Strain ◽  
Machining Process ◽  
Depth Of Cut ◽  
General Corrosion ◽  
Explicit Finite Element ◽  
Finite Element Software ◽  
Cutting Speeds

Titanium (Ti-6Al-4V) alloy is a desirable material for the aircraft industry because of their excellent properties behaves of high specific strength, fracture resistant characteristics, lightweight and general corrosion resistance. This paper presents a study on a two-dimensional orthogonal cutting process by using a face-milling operation through ABAQUS/EXPLICIT finite-element software. Several tests were performed at various feed rates and cutting speeds while the depth of cut remains constant. The results led to the conclusion that the stress components at integration points (Von - Mises) and the equivalent strain (PEEQ) were increased with increasing the feed rate and cutting speed during the machining process.

Rapid Finite Element Prediction on Machining Process

2013 ◽  
Author(s):  
Long Meng ◽  
Xueping Zhang ◽  
Anil K. Srivastava
Keyword(s):  
Finite Element ◽  
Programming Model ◽  
Cutting Speed ◽  
Chip Morphology ◽  
Machining Process ◽  
Fe Model ◽  
Machining Processes ◽  
Machined Surface ◽  
Element Analysis ◽  
Python Language

Finite Element Analysis (FEA) is widely used to simulate machining processes. However, in general, it is time consuming, error-prone, and requires repeated efforts to establish a verified successful Finite Element (FE) model. To rapidly investigate the effects of parameters such as tool angle, feed rate, cutting speed, and temperatures generated during the machining process, an efficient approach is proposed in this paper. The technique has been used to achieve rapid FF simulation during turning and milling processes using Python language programming of Abaqus. Sub-model 1 is programmed to simulate the chip formation process in Abaqus/Explicit. Sub-model 2 is programmed to simulate the cooling spring-back process by importing the machined surface into Abaqus/Implicit. The proposed method is capable of simulating the chip morphology, stress, strain and temperature of the machining process with different parameters immediately. The established FE models are automatically solved in batch by programming script. Post-processing is programmed by Abaqus script to easily achieve and evaluate the simulation results. The Programmed FE models are validated in terms of the predicted chip morphology, cutting forces and residual stresses. This method is extraordinarily efficient saving more than 33% simulation time in comparison to existing FEA approach used for machining processes. Moreover, the script is concise, easy to debug, and effectively avoiding interactive mistakes. The rapid programming model provides a novel, efficiency and convenient approach to thoroughly investigate the effects of a large number of parameters on machining processes.

Modeling of Plastic Behavior of Anisotropic Sheet Metals With Voids

2000 ◽  
Author(s):  
W. Y. Chien ◽  
J. Pan ◽  
S. C. Tang
Keyword(s):  
Finite Element ◽  
Closed Form ◽  
Yield Criterion ◽  
Plastic Anisotropy ◽  
Matrix Material ◽  
Three Dimensional ◽  
Plastic Behavior ◽  
Element Analysis ◽  
Normal Anisotropy ◽  
The Matrix

Abstract The influence of plastic anisotropy on the plastic behavior of porous ductile materials is investigated by a three-dimensional finite element analysis. A unit cell of cube containing a spherical void is modeled. The Hill quadratic anisotropic yield criterion is used to describe the matrix normal anisotropy and planar isotropy. The matrix material is assumed to be elastic perfectly plastic. Macroscopically uniform displacements are applied to the faces of the cube. The finite element computational results are compared with those based on the closed-form anisotropic Gurson yield criterion suggested in Liao et al. (Mechanics of Materials, 1997, pp. 213-226). Three fitting parameters are suggested in the closed-form yield criterion to fit the results based on the modified yield criterion to those of finite element computations.

Finite Element Analysis of Multiphase Viscoelastic Solids

1992 ◽  
Vol 59 (4) ◽  
pp. 730-737 ◽  
Author(s):  
L. C. Brinson ◽  
W. G. Knauss
Keyword(s):  
Finite Element ◽  
Volume Fraction ◽  
Matrix Material ◽  
Numerical Procedure ◽  
Element Model ◽  
Analytical Models ◽  
Frequency Range ◽  
Element Analysis ◽  
The Matrix ◽  
Composite Moduli

The properties of composite solids containing multiple, viscoelastic phases are studied numerically. The dynamic correspondence principle of viscoelasticity is utilized in a finite element model to solve boundary value problems for obtaining global complex moduli of the composite. This numerical procedure accounts for the coupled interactive deformation of the phases and thus the resultant accuracy is limited only by that of finite element analyses in general. The example composite considered in this study contains cylindrical viscoelastic inclusions embedded in a viscoelastic matrix. This investigation focuses on the global composite moduli and their relationship to the individual phase properties as a function of volume fraction. A given phase material is shown to have differing effects on the composite properties, depending on whether it is the continuous or the included phase: In general, the composite moduli are dominated by the matrix material. Comparison is made with two simple analytical models for global effective moduli of composites. “Upper Bounds” reproduce the behavior over the whole frequency range when the matrix is the “stiffer” of the two solids while the “lower bond” associates with the converse arrangement, also over the whole frequency range. The nature of time-temperature behavior of multiphase composite materials is examined in a companion paper.

scholarly journals Finite element analysis and modeling of temperature distribution in turning of titanium alloys

10.30544/323 ◽  
2018 ◽  
Vol 24 (1) ◽  
pp. 59-69 ◽  
Author(s):  
Moola Mohan Reddy ◽  
Mohan Kumar ◽  
Kumaraesan Shanmugam
Keyword(s):  
Finite Element ◽  
Temperature Distribution ◽  
Titanium Alloys ◽  
Cutting Force ◽  
Feed Rate ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Surface Model ◽  
Element Analysis

The titanium alloys (Ti-6Al-4V) have been widely used in aerospace, and medical applications and the demand is ever-growing due to its outstanding properties. In this paper, the finite element modeling on machinability of Ti-6Al-4V using cubic boron nitride and polycrystalline diamond tool in dry turning environment was investigated. This research was carried out to generate mathematical models at 95% confidence level for cutting force and temperature distribution regarding cutting speed, feed rate and depth of cut. The Box-Behnken design of experiment was used as Response Surface Model to generate combinations of cutting variables for modeling. Then, finite element simulation was performed using AdvantEdge®. The influence of each cutting parameters on the cutting responses was investigated using Analysis of Variance. The analysis shows that depth of cut is the most influential parameter on resultant cutting force whereas feed rate is the most influential parameter on cutting temperature. Also, the effect of the cutting-edge radius was investigated for both tools. This research would help to maximize the tool life and to improve surface finish.

Finite Element Analysis of the Distributed Vibration Absorbers for Structural Noise Control

2005 ◽  
Author(s):  
Ashwini Gautam ◽  
Chris Fuller ◽  
James Carneal
Keyword(s):  
Finite Element ◽  
Numerical Model ◽  
Base Plate ◽  
Element Model ◽  
Fe Model ◽  
Vibration Absorbers ◽  
Element Analysis ◽  
Poroelastic Media ◽  
Hexahedral Elements ◽  
Component Models

This work presents an extensive analysis of the properties of distributed vibration absorbers (DVAs) and their effectiveness in controlling the sound radiation from the base structure. The DVA acts as a distributed mass absorber consisting of a thin metal sheet covering a layer of acoustic foam (porous media) that behaves like a distributed spring-mass-damper system. To assess the effectiveness of these DVAs in controlling the vibration of the base structures (plate) a detailed finite elements model has been developed for the DVA and base plate structure. The foam was modeled as a poroelastic media using 8 node hexahedral elements. The structural (plate) domain was modeled using 16 degree of freedom plate elements. Each of the finite element models have been validated by comparing the numerical results with the available analytical and experimental results. These component models were combined to model the DVA. Preliminary experiments conducted on the DVAs have shown an excellent agreement between the results obtained from the numerical model of the DVA and from the experiments. The component models and the DVA model were then combined into a larger FE model comprised of a base plate with the DVA treatment on its surface. The results from the simulation of this numerical model have shown that there has been a significant reduction in the vibration levels of the base plate due to DVA treatment on it. It has been shown from this work that the inclusion of the DVAs on the base plate reduces their vibration response and therefore the radiated noise. Moreover, the detailed development of the finite element model for the foam has provided us with the capability to analyze the physics behind the behavior of the distributed vibration absorbers (DVAs) and to develop more optimized designs for the same.

scholarly journals CAD-Based 3D-FE Modelling of AISI-D3 Turning with Ceramic Tooling

Machines ◽  
2021 ◽  
Vol 9 (1) ◽  
pp. 4
Author(s):  
Panagiotis Kyratsis ◽  
Anastasios Tzotzis ◽  
Angelos Markopoulos ◽  
Nikolaos Tapoglou
Keyword(s):  
Statistical Model ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Fe Model ◽  
Fe Modelling ◽  
3D Finite Element ◽  
Force Components ◽  
Four Levels ◽  
The Relationship ◽  
Strong Agreement

In this study, the development of a 3D Finite Element (FE) model for the turning of AISI-D3 with ceramic tooling is presented, with respect to four levels of cutting speed, feed, and depth of cut. The Taguchi method was employed in order to create the orthogonal array according to the variables involved in the study, reducing this way the number of the required simulation runs. Moreover, the possibility of developing a prediction model based on well-established statistical tools such as the Response Surface Methodology (RSM) and the Analysis of Variance (ANOVA) was examined, in order to further investigate the relationship between the cutting speed, feed, and depth of cut, as well as their influence on the produced force components. The findings of this study point out an increased correlation between the experimental results and the simulated ones, with a relative error below 10% for most tests. Similarly, the values derived from the developed statistical model indicate a strong agreement with the equivalent numerical values due to the verified adequacy of the statistical model.

scholarly journals Design and analysis of concrete-filled tubular flange girders under combined loading

2021 ◽  
pp. 136943322110015
Author(s):  
Rana Al-Dujele ◽  
Katherine Ann Cashell
Keyword(s):  
Finite Element ◽  
Axial Force ◽  
Failure Modes ◽  
Numerical Study ◽  
Combined Loading ◽  
Torsional Stiffness ◽  
Fe Model ◽  
Combined Effects ◽  
Element Analysis ◽  
Hollow Section

This paper is concerned with the behaviour of concrete-filled tubular flange girders (CFTFGs) under the combination of bending and tensile axial force. CFTFG is a relatively new structural solution comprising a steel beam in which the compression flange plate is replaced with a concrete-filled hollow section to create an efficient and effective load-carrying solution. These members have very high torsional stiffness and lateral torsional buckling strength in comparison with conventional steel I-girders of similar depth, width and steel weight and are there-fore capable of carrying very heavy loads over long spans. Current design codes do not explicitly include guidance for the design of these members, which are asymmetric in nature under the combined effects of tension and bending. The current paper presents a numerical study into the behaviour of CFTFGs under the combined effects of positive bending and axial tension. The study includes different loading combinations and the associated failure modes are identified and discussed. To facilitate this study, a finite element (FE) model is developed using the ABAQUS software which is capable of capturing both the geometric and material nonlinearities of the behaviour. Based on the results of finite element analysis, the moment–axial force interaction relationship is presented and a simplified equation is proposed for the design of CFTFGs under combined bending and tensile axial force.

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