Tool-Chip Friction and Two-Dimensional Numerical Simulation Analysis of High-Speed Milling AISI304

2015 ◽  
Vol 1089 ◽  
pp. 377-380
Author(s):  
Lin Lin Guo ◽  
Guang Hui Li ◽  
Ning Xia Yin ◽  
Guang Yu Tan
Keyword(s):  
Finite Element ◽  
High Speed ◽  
Simulation Analysis ◽  
Chip Morphology ◽  
Element Model ◽  
Simulation Method ◽  
State Theory ◽  
Friction Model ◽  
Two Dimensional ◽  
High Speed Milling

The physical friction system model was established between the tool and the chip based on the analysis of tri-bological behavior of high speed milling process of the end mill. The finite element simulation method was employed to study the tool-chip friction model, and the two-dimensional(2D) finite element model of milling was created. The numerical results revealed the chip morphology, stress and temperature distribution of the tool-chip contact surface. The tool temperature field distribution provided supports for tool-chip friction state theory and the 3D milling model.

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.

Computer Simulation of AISI D2 Orthogonal Cutting Using Finite Element Method

2012 ◽  
Vol 499 ◽  
pp. 39-44
Author(s):  
L. Yan ◽  
Feng Jiang ◽  
Y.M. Rong
Keyword(s):  
Finite Element ◽  
High Speed ◽  
Cutting Tool ◽  
Orthogonal Cutting ◽  
Damage Model ◽  
Chip Morphology ◽  
Simulation Method ◽  
Cutting Process ◽  
Aisi D2 ◽  
Cutting Processes

This paper presented a finite element simulation model for the analysis of AISI D2 orthogonal cutting process using TiAlN coated inserts. Firstly, AISI D2 material constitutive model was built based on power law model, which was used in the FEM codes to describe the effect of strain, strain rate and temperature on the material flow stress. In modeling the chip formation, a damage model was employed to predict the chip separation. Then cutting edge radius and thickness of TiAlN coating of cutting tool were measured by SEM. Friction coefficients of cutting tool against AISI D2 steel were obtained by ball-on-plate friction tests on UMT-2 high speed tribometer. Finally, finite element simulations of AISI D2 orthogonal cutting processes were performed using AdvantedgeTM software. The simulated results of cutting forces and chip morphology showed good agreement with the experimental results, which validated the reliability of the cutting process simulation method.

Identification and Validation of Marusich’s Constitutive Law for Finite Element Modeling of High Speed Machining

2014 ◽  
Author(s):  
Walid Jomaa ◽  
Monzer Daoud ◽  
Victor Songmene ◽  
Philippe Bocher ◽  
Jean-François Châtelain
Keyword(s):  
Finite Element ◽  
High Speed ◽  
Chip Morphology ◽  
Material Model ◽  
Element Model ◽  
Contact Length ◽  
Constitutive Law ◽  
High Speed Machining ◽  
Orthogonal Machining ◽  
Deform 2D

This study aims to identify the coefficients of Marusich’s constitutive equation (MCE) for the aluminum AA7075-T651. Material constants were identified inversely form orthogonal machining tests and from dynamic tests. The proposed material model was successfully implemented in a finite element model (FEM) to simulate the high speed machining of the aluminum AA7075-T6. Deform 2D® software was used. A reasonable agreement between predictions and experiments was obtained. The comparison was based on cutting forces, chip morphology, and tool/chip contact length.

Numerical Simulation Study of High-Speed Milling Thin-Wall Part

2011 ◽  
Vol 239-242 ◽  
pp. 801-805 ◽  
Author(s):  
De Wen Tang ◽  
Ru Shu Peng ◽  
Rui Lan Zhao
Keyword(s):  
Numerical Simulation ◽  
Finite Element ◽  
Cutting Force ◽  
Effective Stress ◽  
High Speed ◽  
Cutting Temperature ◽  
Chip Morphology ◽  
Thin Wall ◽  
High Speed Milling ◽  
Thin Wall Part

According to the weak rigidity characteristics of thin-walled parts, the material parameters and deformation tools are taken into account. In this paper, the finite element model of high-speed milling process is systematically studied by a large-scale finite element analysis (FEA) software DEFORM-3D with the modified Johnson-Cook model. The simulated results of cutting force, chip morphology, effective stress, effective strain and cutting temperature in deformation zones of thin-wall part are analyzed. On the basis of simulation results, cutting force of high speed milling on thin-wall part is verified. Comparing to the experimental results, the simulated results of cutting force, chip morphology, effective stress and cutting temperature in deformation zones of high speed peripheral milling indicate good consistence and the models established can be used to accurately predict the thin wall deformation. Therefore, numerical simulation method for the thin wall milling deformation control and provide a new way of compensation.

scholarly journals SIMULATION STUDIES ON CHIP FORMATION PROCESS IN HIGH SPEED MILLING OF ALUMINIUM ALLOY

2018 ◽  
Vol 54 (5A) ◽  
pp. 174
Author(s):  
Pham Thi Hoa
Keyword(s):  
Finite Element ◽  
Aluminium Alloy ◽  
High Speed ◽  
Equivalent Plastic Strain ◽  
Cutting Parameters ◽  
Element Model ◽  
Von Mises Stress ◽  
High Speed Milling ◽  
Von Mises ◽  
Cutting Processes

Simulations of chip formulation mechanism and phenomenon ccurred in cutting processes can help to reduce time and cost comparing with experiment. Finite element method (FEM) is an effective and accurate technique, which can be used for simulation of cutting process. In this paper, chip formulation process in high-speed milling of A6061 aluminium alloy is investigated using FEM based on the Johnson-Cook (J-C) and Bao-Wierzbicki (B-W) fracture models. The Von-Mises stress distribution and equivalent plastic strain (PEEQ) during cutting are then investigated. Finally, the evolution of cutting forces in cutting was examined. The presented Finite element model in this study proved to be useful in determination of cutting parameters, especially in high-speed machining. 

Mechanics Modeling and Three-Dimensional Finite Element Simulating for High Speed Milling of Titanium Alloy

2010 ◽  
Vol 29-32 ◽  
pp. 360-364
Author(s):  
Yong Yang ◽  
Yu Ling Wang ◽  
Chang He Li
Keyword(s):  
Finite Element ◽  
Titanium Alloy ◽  
Finite Element Model ◽  
High Speed ◽  
Three Dimensional ◽  
Element Model ◽  
Milling Process ◽  
High Speed Milling ◽  
Dimensional Finite Element ◽  
Three Dimensional Finite Element

A three-dimensional finite element model of helix double-edge cutting is developed to study the ending milling process of titanium alloy Ti6Al4V. Several mechanics models of milling process, such as material constitutive model, friction model and heat transfer model, are implemented to improve finite element simulating accuracy. A milling force experiment is carried out, and a good agreement between simulation and experimental value is achieved, which proved that the finite element model presented in this paper is correct. Using this finite element model, chip formation and cutting temperature are simulated and analyzed. This work will be a base for process parameter optimization, tool’s optimization selection and design during high speed milling of difficult-to-cut titanium alloy.

Finite Element Simulation of Chip Formation during High-Speed Peripheral Milling of Hardened Mold Steel

2010 ◽  
Vol 443 ◽  
pp. 274-278 ◽  
Author(s):  
De Weng Tang ◽  
Cheng Yong Wang ◽  
Ying Ning Hu ◽  
Yue Xian Song
Keyword(s):  
Finite Element ◽  
Chip Formation ◽  
High Speed ◽  
Cutting Temperature ◽  
Chip Morphology ◽  
Peripheral Milling ◽  
Element Analysis ◽  
High Speed Milling ◽  
Element Simulation ◽  
The Finite Element Analysis

The modeling and simulation of chip formation during high speed milling of hardened mold steel are systematically studied by the Finite Element Analysis (FEA). The modified Johnson-Cook’s constitutive equation for hardened mold steel is introduced. Comparing to the experimental results, the simulated results of cutting force, chip morphology, effective stress and cutting temperature in deformation zones of high speed peripheral milling indicate good consistence and the models established can be used to accurately predict the behavior of hardened mold steel.

Research on Numerical Simulation of High-Speed Railway Noise Barrier Aerodynamic Pressure

2013 ◽  
Vol 274 ◽  
pp. 45-48 ◽  
Author(s):  
Hong Mei Li ◽  
Yan Xuan ◽  
Lan Wang ◽  
Yan Liang Li ◽  
Xing Fang ◽  
...  
Keyword(s):  
Finite Element ◽  
Structural Design ◽  
High Speed ◽  
Extreme Values ◽  
Element Model ◽  
Simulation Method ◽  
Noise Barriers ◽  
Aerodynamic Pressure ◽  
Wind Pressures ◽  
Fluctuating Wind

Based on finite volume method of finite element method, the aerodynamics models of the train passing through bridge noise barriers (high respectively, for 2.15m, 1.93m) and the subgrade (high respectively, for 2.95m,3.95m) noise barriers is established by large commercial fluid dynamics calculation software. The three dimensional transient outflow field is numerical simulated by applying dynamic mesh technology and large eddy simulation method (LES) for the train passing through noise barriers. The extreme value, schedule curve and pressure cloud contour of fluctuating wind pressures of the different height noise barriers on bridge and roadbed are acquired for 300 ~ 420 km/h different speeds. Extreme values of fluctuating wind pressures product by trains with different speeds are contrast analyzed. The simulation results are very close to the experimental data, proves the validity and feasibility of the finite element model and the accuracy of the parameters. This research provides the theory support to the structural design of the noise barriers and can effectively guide the structural design of the noise barriers.

Finite Element Analysis for Thermal Characteristics of High Speed Angular Contact Ball Bearing

2013 ◽  
Vol 397-400 ◽  
pp. 126-130
Author(s):  
Peng Wang ◽  
Chun Li Lei ◽  
Bao Cheng Zhou ◽  
Wei Ping Zhao
Keyword(s):  
Heat Transfer ◽  
Finite Element ◽  
High Speed ◽  
Ball Bearing ◽  
Simulation Analysis ◽  
Cooling System ◽  
Thermal Characteristics ◽  
Element Model ◽  
Angular Contact Ball Bearing ◽  
Element Analysis

According to the high speed bearing failure problem caused by the high temperature, finite element model of high-speed hybrid ceramic angular contact ball bearing is established in this paper. Quantity of heat and heat transfer coefficient are calculated by using the heat transfer and thermodynamics theory, which are boundary condition for the temperature field simulation analysis of ball bearing. The temperature distribution of bearing is obtained when bearing speed is 12000rad/min. The results can provide a theoretical foundation for lubrication cooling system controlling temperature.

Simulation Analysis of Thermodynamics on the Belt Spindle of the Machining Center

2013 ◽  
Vol 690-693 ◽  
pp. 3240-3243
Author(s):  
Qiang He ◽  
An Ling Li ◽  
Yong Zhang ◽  
Ye Jun ◽  
Xin Sheng Li
Keyword(s):  
Thermal Analysis ◽  
Finite Element ◽  
Temperature Rise ◽  
Structural Design ◽  
High Speed ◽  
Simulation Analysis ◽  
Element Model ◽  
The Finite Element Method ◽  
Machining Center ◽  
The Finite Element Model

By taking the belt spindle of the machining center high speed and high precision as the research object, using the finite element method, the Solidworks software is used to make the thermal analysis. In this paper, we define the boundary conditions and thermal load of the spindle thermal analysis, and establish the finite element model. The steady-state thermal analysis and temperature rise is simulated, and the temperature distribution is predicted by using Solidworks software. The results show that the structural design of the belt spindle is reasonable, and the temperature rise is in the control range.

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