Simulations of Milling Process of Inconel 718 Alloy Based on Three Dimensional Finite Element Models

2014 ◽  
Vol 1017 ◽  
pp. 399-405 ◽  
Author(s):  
Lin Jiang He ◽  
Hong Hua Su ◽  
Jiu Hua Xu ◽  
Jia Bao Fu
Keyword(s):  
Finite Element ◽  
Cutting Forces ◽  
Inconel 718 ◽  
Metal Removal ◽  
Cutting Temperature ◽  
Milling Process ◽  
Material Behavior ◽  
Tool Geometry ◽  
Mass Scaling ◽  
Element Removal

Nickel-based alloy is known as one of the most difficult–to-machine materials and the milling process is one of the most common metal removal operations. Modeling and simulation of milling process have the potential for understanding the milling mechanism, improving cutting tool designs and selecting optimum conditions, especially in advanced applications such as high-speed milling. This paper presents a 3D coupled thermo-mechanical finite element model based on ABAQUS\Explicit for the simulation of Inconel 718 chip formation in metal cutting. In the simulations, a Lagrangian formulation with an explicit solution scheme and a penalty contact algorithm has been used. The material behavior is modeled with classical Johnson-cook plasticity constitutive model and dynamic failure criteria for element removal, coupled with adaptive meshing and mass scaling technology for limiting the calculation time. The milling tool is modeled in UG software according to the real tool geometry, and meshed as a rigid tool. In order to verify the accuracy of 3D simulation, results (cutting forces and cutting temperature) were compared with the experimental results under the same cutting conditions as the simulations. The results obtained indicate that the simulation methodology is capable of predicting the cutting forces and cutting temperature. It suggests that 3D finite element simulation model of cutting processes can be truly trusted.

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.

The flank wear prediction in micro-milling Inconel 718

2018 ◽  
Vol 70 (8) ◽  
pp. 1374-1380 ◽  
Author(s):  
Xiaohong Lu ◽  
FuRui Wang ◽  
Zhenyuan Jia ◽  
Steven Y. Liang
Keyword(s):  
Finite Element ◽  
Tool Wear ◽  
Cutting Forces ◽  
Inconel 718 ◽  
Flank Wear ◽  
Milling Process ◽  
Micro Milling ◽  
Wear Prediction ◽  
Content Type ◽  
Micro Tool

Purpose Cutting tool wear is known to affect tool life, surface quality, cutting forces and production time. Micro-milling of difficult-to-cut materials like Inconel 718 leads to significant flank wear on the cutting tool. To ensure the respect of final part specifications and to study cutting forces and tool catastrophic failure, flank wear (VB) has to be controlled. This paper aims to achieve flank wear prediction during micro-milling process, which fills the void of the commercial finite element software. Design/methodology/approach Based on tool geometry structure and DEFORM finite element simulation, flank wear of the micro tool during micro-milling process is obtained. Finally, experiments of micro-milling Inconel 718 validate the accuracy of the proposed method for predicting flank wear of the micro tool during micro-milling Inconel 718. Findings A new prediction method for flank wear of the micro tool during micro-milling Inconel 718 based on the assumption that the wear volume can be assumed as a cone-shaped body is proposed. Compared with the existing experiment techniques for predicting tool wear during micro-milling process, the proposed method is simple to operate and is cost-effective. The existing finite element investigations on micro tool wear prediction mainly focus on micro tool axial wear depth, which affects size accuracy of machined workpiece seriously. Originality/value The research can provide significant knowledge on the usage of finite element method in predicting tool wear condition during micro-milling process. In addition, the method presented in this paper can provide support for studying the effect of tool flank wear on cutting forces during micro-milling process.

scholarly journals Finite element simulation and experimental validation of the effect of tool wear on cutting forces in turning operation

2019 ◽  
Vol 23 (1) ◽  
pp. 297-302 ◽  
Author(s):  
S. Sai Venkatesh ◽  
T. A. Ram Kumar ◽  
A. P. Blalakumhren ◽  
M. Saimurugan ◽  
K. Prakash Marimuthu
Keyword(s):  
Finite Element ◽  
Tool Wear ◽  
Cutting Forces ◽  
Metal Cutting ◽  
Damage Model ◽  
Friction Model ◽  
Material Behavior ◽  
Experimental Results ◽  
Tool Geometry ◽  
Work Piece

Abstract Machining is the most widely used process in manufacturing, and tool wear plays a significant role in machining efficiency and effectiveness. There is a continuous requirement to manufacture high-quality products at a lower cost. Many past researches show that variations in tool geometry affect the cutting forces significantly. The increase in cutting forces leads to excessive vibrations in the system, giving a poor surface finish to the machined product. In this work, a 2D coupled thermo-mechanical model is developed using Abaqus/Explicit to predict the cutting forces during turning of mild steel. Johnson–Cook material model along with damage model has been used to define the material behavior. Coulomb’s friction model is considered for defining the interaction between the tool and the work piece. Metal cutting process is simulated for different sets of cutting conditions and compared with experimental results. The finite element method results correlate well with the experimental results.

Predicting the High Speed Cutting Process of Titanium Alloy by Finite Element Method

2011 ◽  
Author(s):  
Xiangqin Zhang ◽  
Xueping Zhang ◽  
A. K. Srivastava
Keyword(s):  
Finite Element ◽  
Cutting Forces ◽  
High Speed ◽  
Cutting Temperature ◽  
Chip Morphology ◽  
Cutting Process ◽  
Fe Model ◽  
Dry Cutting ◽  
Friction Coefficients ◽  
Machining Conditions

To predict the cutting forces and cutting temperatures accurately in high speed dry cutting Ti-6Al-4V alloy, a Finite Element (FE) model is established based on ABAQUS. The tool-chip-work friction coefficients are calculated analytically using the measured cutting forces and chip morphology parameter obtained by conducting the orthogonal (2-D) machining tests. It reveals that the friction coefficients between tool-work are 3∼7 times larger than that between tool-chip, and the friction coefficients of tool-chip-work vary with feed rates. The analysis provides a better reference for the tool-work-chip friction coefficients than that given by literature empirically regardless of machining conditions. The FE model is capable of effectively simulating the high speed dry cutting process of Ti-6Al-4V alloy based on the modified Johnson-Cook model and tool-work-chip friction coefficients obtained analytically. The FE model is further validated in terms of predicted forces and the chip morphology. The predicted cutting force, thrust force and resultant force by the FE model agree well with the experimentally measured forces. The errors in terms of the predicted average value of chip pitch and the distance between chip valley and chip peak are smaller. The FE model further predicts the cutting temperature and residual stresses during high speed dry cutting of Ti-6Al-4V alloy. The maximum tool temperatures exist along the round tool edge, and the residual stress profiles along the machined surface are hook-shaped regardless of machining conditions.

An Approach on Fuzzy and Regression Modeling for Hard Milling Process

2015 ◽  
Vol 813-814 ◽  
pp. 498-504 ◽  
Author(s):  
A. Tamilarasan ◽  
D. Rajamani ◽  
A. Renugambal
Keyword(s):  
Manufacturing Systems ◽  
Metal Removal ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Milling Process ◽  
Regression Modeling ◽  
Average Error ◽  
Depth Of Cut ◽  
Hard Milling ◽  
Radial Depth

This paper proposes the prediction of cutting temperature, tool wear and metal removal rate using fuzzy and regression modeling techniques for the hard milling process. The feed per tooth, radial depth of cut, axial depth of cut and cutting speed were used as process state variables.The experiements were conducted using RSM based central composite rotatable design methodology. Regression and fuzzy modeling were used to evaluate the input – output relationship in the process. It is interesting to observe that the R2 and average error values for each response are very consistent with small variations were obtained.Also, the confirmation results show that very less relative error varitions. Thus, the developed fuzzy models directly integrated in manufacturing systems to reduce the more computational complexity in the process planning activities.

On the Optimized Design of Broaching Tools

2013 ◽  
Vol 136 (1) ◽  
Author(s):  
A. Hosseini ◽  
H. A. Kishawy
Keyword(s):  
Cutting Forces ◽  
Cutting Tool ◽  
Metal Removal ◽  
Removal Rate ◽  
Geometric Model ◽  
Design Procedure ◽  
Tool Geometry ◽  
Manufacturing Cost ◽  
Force Model ◽  
Optimized Design

Among the cutting tools that are utilized in industry broaching tools are the most expensive ones. Unlike other machining operations such as milling and turning in which a cutting tool can be used for producing a variety of shapes, the broaching tools are uniquely designed depending on the desired profile to be produced on the workpiece. Consequently, the shape of broaching tools may be altered from one case to the others. This shape can be a simple keyway or a complicated fir tree on a turbine disk. Hence, a proper design of the broaching tools has the highest priority in broaching operation. Every single feature of these expensive tools must be accurately designed to increase productivity, promote part quality and reduce manufacturing cost. A geometric model of the cutting tool and a predictive force model to estimate the cutting forces are two fundamental requirements in simulation of any machining operation. This paper presents a geometric model for the broaching tools and a predictive force model for broaching operations. The broaching tooth is modeled as a cantilevered beam and the cutting forces are predicted based on the energy spent in the cutting system. A design procedure has been also developed for identification of the optimized tool geometry aiming to achieve maximum metal removal rate (MRR) by considering several physical and geometrical constraints.

FINITE ELEMENT CHIP FORMATION ANALYSIS FOR HIGH SPEED MILLING OPERATIONS

2008 ◽  
Vol 32 (3-4) ◽  
pp. 513-522
Author(s):  
Usama Umer ◽  
Lijing Xie ◽  
Xibin Wang
Keyword(s):  
Finite Element ◽  
Cutting Forces ◽  
High Speed ◽  
End Milling ◽  
Element Model ◽  
Hardened Steel ◽  
Tool Geometry ◽  
Successful Implementation ◽  
Flat Bottom ◽  
Milling Operations

High speed end milling of hardened steel offers several advantages over EDM in die/molds applications especially due to recent development in machine tools, spindles and controllers. However successful implementation of this technology is limited mainly due to faster tool wear and undesirable surface properties. Finite element modeling and simulation techniques are capable of optimizing the cutting conditions and tool geometry by predicting the temperature and stresses distributions. In this study a finite element model has been developed to predict cutting forces, temperature and stresses distributions in flat end milling processes of hardened steel using PCBN at high cutting speeds. High speed end milling experiments were conducted using flat bottom end mills with single insert having straight cutting edge. Comparison of simulated and experimental cutting forces data shows reasonable agreement at high speed regime using the developed model.

Effects of the Flow Stress in Finite Element Simulation of Machining Inconel 718 Alloy

2014 ◽  
Vol 611-612 ◽  
pp. 1210-1216 ◽  
Author(s):  
Farshid Jafarian ◽  
Mikel Imaz Ciaran ◽  
Pedro José Arrazola ◽  
Luigino Filice ◽  
Domenico Umbrello ◽  
...  
Keyword(s):  
Finite Element ◽  
Finite Element Simulation ◽  
Inconel 718 ◽  
Orthogonal Cutting ◽  
Material Model ◽  
Material Behavior ◽  
Machining Process ◽  
Inconel 718 Alloy ◽  
Element Simulation ◽  
Inconel 718 Superalloy

Inconel 718 superalloy is one of the difficult-to-machine materials which is employed widely in aerospace industries because of its superior properties such as heat-resistance, high melting temperature, and maintenance of strength and hardness at high temperatures. Material behavior of the Inconel 718 is an important challenge during finite element simulation of the machining process because of the mentioned properties. In this regard, various constants for Johnson–Cook’s constitutive equation have been reported in the literature. Owing to the fact that simulation of machining process is very sensitive to the material model, in this study the effect of different flow stresses were investigated on outputs of the orthogonal cutting process of Inconel 718 alloy. For each model, the predicted results of cutting forces, chip geometry and temperature were compared with experimental results of the previous work at the different feed rates. After comparing the results of the different models, the most suitable Johnson–Cook’s material model was indentified. Obtained results showed that the selected material model can be used reliably for machining simulation of Inconel 718 superalloy.

Finite Element Modeling of Edge Trimming Fiber Reinforced Plastics

2000 ◽  
Vol 124 (1) ◽  
pp. 32-41 ◽  
Author(s):  
D. Arola ◽  
M. B. Sultan ◽  
M. Ramulu
Keyword(s):  
Finite Element ◽  
Finite Element Model ◽  
Cutting Forces ◽  
Cutting Tool ◽  
Deformable Body ◽  
Orthogonal Cutting ◽  
Element Model ◽  
Tool Geometry ◽  
Reinforced Plastics ◽  
Edge Trimming

A finite element model was developed to simulate chip formation in the edge trimming of unidirectional Fiber Reinforced Plastics (FRPs) with orthogonal cutting tools. Fiber orientations (θ) within the range of 0 deg⩽θ⩽90 deg were considered and the cutting tool was modeled as both a rigid and deformable body in independent simulations. The principal and thrust force history resulting from numerical simulations for orthogonal cutting were compared to those obtained from edge trimming of unidirectional Graphite/Epoxy (Gr/Ep) using polycrystalline diamond tools. It was found that principal cutting forces obtained from the finite element model with both rigid and deformable body tools compared well with experimental results. Although the cutting forces increased with increasing fiber orientation, the tool rake angle had limited influence on cutting forces for all orientations other than θ=0 deg and 90 deg. However, the tool geometry did affect the degree of subsurface damage resulting from interlaminar shear failure as well as the cutting tool stress distribution. The finite element model for chip formation provides a means for optimizing tool geometry over the total range in fiber orientations in terms of the cutting forces, degree of subsurface trimming damage, and the cutting tool stresses.

Finite Element Simulation of the Cutting Process for Inconel 718 Alloy Using a New Material Constitutive Model

2016 ◽  
Vol 693 ◽  
pp. 1046-1053
Author(s):  
Xiang Yu Wang ◽  
Chuan Zhen Huang ◽  
Jun Wang ◽  
Bin Zou ◽  
Guo Liang Liu ◽  
...  
Keyword(s):  
Finite Element ◽  
Constitutive Model ◽  
Finite Element Simulation ◽  
Cutting Forces ◽  
Inconel 718 ◽  
Cutting Process ◽  
Inconel 718 Alloy ◽  
Cutting Edge Radius ◽  
Material Constitutive Model ◽  
Element Simulation

Inconel 718 alloy is a typical difficult-to-cut material and widely used in the aerospace industry. Finite element simulation is an efficient method to investigate the cutting process, whereby a work material constitutive model plays an important role. In this paper, finite element simulation of the cutting process for Inconel 718 alloy using a new material constitutive model for high strain rates is presented. The effect of tool cutting edge radius on the cutting forces and temperature is then investigated with a view to facilitate cutting tool design. It is found that as the cutting edge radius increases, the characteristics of tool-work friction and the material removal mechanisms change, resulting in variation in cutting forces and temperature. It is shown that a smaller cutting edge radius is preferred to reduce the cutting forces and cutting temperature.

Sign in / Sign up

Export Citation Format

Share Document