3D Finite Element Simulation on the Orthogonal Cutting Processes with Different Commercial Codes

2011 ◽  
Vol 188 ◽  
pp. 555-560
Author(s):  
Zhao Yu Mou ◽  
Peng Fei Gao ◽  
Wei Fang Wang ◽  
Dong Hui Wen
Keyword(s):  
Finite Element ◽  
Metal Cutting ◽  
Orthogonal Experiment ◽  
Orthogonal Cutting ◽  
Friction Model ◽  
Element Simulation ◽  
Cutting Experiment ◽  
Type Boundary ◽  
Cutting Processes ◽  
Type Boundary Condition

The purpose of this paper is to compare different simulation model of orthogonal cutting process using three different FEM commercial codes as well as with the results of orthogonal experiment. For one thing, element type, boundary condition and friction model between the chip and tool commercial have been compared when the numerical model established in implicit finite element code, Deform3D and the explicit code ANSYS/LS-DYNA and Thirdwave AdvantEdge. For another, main and thrust cutting forces, shear angles, chip thicknesses and contact lengths by three codes are compared with the orthogonal metal cutting experiment by Movahhedy and Altintas.

The Finite Element Simulation of Milling Based on Orthogonal Cutting Model

2012 ◽  
Vol 499 ◽  
pp. 208-212
Author(s):  
Ai Hua Gao ◽  
Fu Rong Wang ◽  
Jian Xin Zhang
Keyword(s):  
Finite Element ◽  
Service Life ◽  
Finite Element Simulation ◽  
Metal Cutting ◽  
Orthogonal Cutting ◽  
Milling Process ◽  
Machining Process ◽  
Element Simulation ◽  
Basic Parameters ◽  
Cutting Model

The paper make the service life of relieving formed milling cutter as the optimization objective, proceed the simulation study on the mechanical degree of cutter, cutting data. The concrete method is that the orthogonal milling model is established to simulate the simulation milling process, some basic parameters which are obtained in the machining process are analyzed and discussed. The results indicate that the finite element simulation of the metal cutting processing can analyze quantitatively some physical properties, such as the cutting force, stress, strain and so on, the traditional way of qualitative analysis is changed. The state of machining is in favour of grasping in the theory, the theory and technology are provided to establish the proper processing technology strategy.

The Establishment of Orthogonal Cutting Finite Element Model and its Key Technologies

2009 ◽  
Vol 416 ◽  
pp. 568-571
Author(s):  
You Yi Zheng ◽  
Ai Hua Gao
Keyword(s):  
Finite Element ◽  
Finite Element Model ◽  
Metal Cutting ◽  
Orthogonal Cutting ◽  
Element Model ◽  
Key Technology ◽  
Element Simulation ◽  
Key Technologies ◽  
Orthogonal Metal Cutting ◽  
The Finite Element Model

Based on several assumptions, this paper established the finite element model of the heat coupling of the orthogonal metal cutting, and analyzes the key technology that involved in the Orthogonal cutting finite element simulation.

Finite Element Simulation of the Orthogonal Cutting Based on Abaqus

2013 ◽  
Vol 821-822 ◽  
pp. 1410-1413 ◽  
Author(s):  
Xue Bin Liu ◽  
Xi Bin Wang ◽  
Chong Ning Li ◽  
San Peng Deng
Keyword(s):  
Finite Element ◽  
Finite Element Simulation ◽  
Orthogonal Cutting ◽  
Element Model ◽  
Friction Model ◽  
Cutting Process ◽  
Work Piece ◽  
Conduction Model ◽  
Element Analysis ◽  
Element Simulation

In view of orthogonal cutting, finite element simulation geometry is built. the friction model, thermal conduction model and chip separation model are established between chip and tool using Abaqus which is a finite element analysis software. Through a specific example, two-dimensional finite element model have been established, simulating the cutting process stress distribution of the work piece surface is also obtained during processing. While simulation analyzes the relationship between the rake angle and shear angle, the results of simulation and experiment are basically the same, thus further verify the credibility of Abaqus simulation results on orthogonal cutting, and the feasible is also proved of obtaining cutting data by the use of Abaqus simulation cutting process.

Evaluation of Ductile Fracture Models in Finite Element Simulation of Metal Cutting Processes

2013 ◽  
Vol 136 (1) ◽  
Author(s):  
Jian Liu ◽  
Yuanli Bai ◽  
Chengying Xu
Keyword(s):  
Finite Element ◽  
Ductile Fracture ◽  
Damage Evolution ◽  
Metal Cutting ◽  
Fracture Criterion ◽  
Orthogonal Cutting ◽  
Systematic Evaluation ◽  
Fe Model ◽  
Fracture Models ◽  
Cutting Processes

In this paper, a systematic evaluation of six ductile fracture models is conducted to identify the most suitable fracture criterion for metal cutting processes. Six fracture models are evaluated in this study, including constant fracture strain, Johnson-Cook, Johnson-Cook coupling criterion, Wilkins, modified Cockcroft-Latham, and Bao-Wierzbicki fracture criterion. By means of abaqus built-in commands and a user material subroutine (VUMAT), these fracture models are implemented into a finite element (FE) model of orthogonal cutting processes in abaqus/Explicit platform. The local parameters (stress, strain, fracture factor, and velocity fields) and global variables (chip morphology, cutting forces, temperature, shear angle, and machined surface integrity) are evaluated. The numerical simulation results are examined by comparing to experimental results of 2024-T3 aluminum alloy published in the open literature. Based on the results, it is found that damage evolution should be considered in cutting process FE simulation. Moreover, the B-W fracture model with consideration of rate dependency, temperature effect and damage evolution gives the best prediction of chip removal behavior of ductile metals.

Finite Element Simulation of the Orthogonal Metal Cutting Process

2004 ◽  
Vol 471-472 ◽  
pp. 582-586 ◽  
Author(s):  
Shi Jin Chen ◽  
Q.L. Pang ◽  
K. Cheng
Keyword(s):  
Finite Element ◽  
Metal Cutting ◽  
Orthogonal Cutting ◽  
Element Model ◽  
Cutting Process ◽  
Machined Surface ◽  
Cutting Test ◽  
Orthogonal Metal Cutting ◽  
Discontinuous Cutting ◽  
Cutting Processes

In this paper, a finite element model of a two-dimensional orthogonal metal cutting process is used to simulate the chip formation, cutting forces, stress, strain and temperature distributions. Two deformable parts are involved in this model: the workpiece and the cutting tool. To make the results of the simulation agree the orthogonal cutting test better, the separation surface between the chip and the machined surface is not predefined in this simulation. The chip-separation criterion is based on the Johnson and Cook law. This work will help as a reference to tackle more complex cutting processes such as oblique and discontinuous cutting.

3D Finite Element Simulation for Turning of Hardened 45 Steel

2019 ◽  
Vol 13 (2) ◽  
pp. 181-188
Author(s):  
Meng Liu ◽  
Guohe Li ◽  
Xueli Zhao ◽  
Xiaole Qi ◽  
Shanshan Zhao
Keyword(s):  
Finite Element ◽  
Finite Element Model ◽  
Cutting Force ◽  
Finite Element Simulation ◽  
Orthogonal Experiment ◽  
Element Model ◽  
3D Finite Element ◽  
Element Simulation ◽  
Metal Machining ◽  
Single Factor Experiment

Background: Finite element simulation has become an important method for the mechanism research of metal machining in recent years. Objective: To study the cutting mechanism of hardened 45 steel (45HRC), and improve the processing efficiency and quality. Methods: A 3D oblique finite element model of traditional turning of hardened 45 steel based on ABAQUS was established in this paper. The feasibility of the finite element model was verified by experiment, and the influence of cutting parameters on cutting force was predicted by single factor experiment and orthogonal experiment based on simulation. Finally, the empirical formula of cutting force was fitted by MATLAB. Besides, a lot of patents on 3D finite element simulation for metal machining were studied. Results: The results show that the 3D oblique finite element model can predict three direction cutting force, the 3D chip shape, and other variables of metal machining and the prediction errors of three direction cutting force are 5%, 9.02%, and 8.56%. The results of single factor experiment and orthogonal experiment are in good agreement with similar research, which shows that the model can meet the needs for engineering application. Besides, the empirical formula and the prediction results of cutting force are helpful for the parameters optimization and tool design. Conclusion: A 3D oblique finite element model of traditional turning of hardened 45 steel is established, based on ABAQUS, and the validation is carried out by comparing with experiment.

scholarly journals Adaptive Particle Finite Element Method (A‐PFEM) in Metal Cutting Processes

PAMM ◽  
2021 ◽  
Vol 20 (1) ◽  
Author(s):  
Xialong Ye ◽  
Juan Manuel Rodríguez Prieto ◽  
Ralf Müller
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Metal Cutting ◽  
Particle Finite Element Method ◽  
Cutting Processes ◽  
Element Method

scholarly journals Particle Finite Element Simulation of Chip Formation in Cutting Processes

2017 ◽  
Vol 869 ◽  
pp. 50-61
Author(s):  
Matthias Sabel ◽  
Christian Sator ◽  
Ralf Müller ◽  
Benjamin Kirsch
Keyword(s):  
Finite Element ◽  
Structural Integrity ◽  
Large Deformations ◽  
Element Formulation ◽  
Particle Finite Element Method ◽  
Element Simulation ◽  
Modeling Techniques ◽  
Cutting Processes ◽  
The Impact ◽  
Cutting Simulations

The formation of chips in cutting processes is characterised by large deformations and large configurational changes and therefore challenges established modeling techniques. To overcome these difficulties, the particle finite element method (PFEM) combines the benefits of discrete modeling techniques with methods based on continuum mechanics. In this work an outline of the PFEM, as well as an explanation of the finite element formulation are provided. The impact of the boundary detection on the structural integrity is studied. The numerical examples include a tensile test as well as cutting simulations. The paper is concluded by a comparison of cutting forces with analytical results.

scholarly journals Investigation of the Cutting Uid'S Ow and its Thermomechanical Effect on the Cutting Zone Based on Uid-Structure Interaction (FSI) Simulation

2021 ◽  
Author(s):  
Hui Liu ◽  
Markus Meurer ◽  
Daniel Schraknepper ◽  
Thomas Bergs
Keyword(s):  
Metal Cutting ◽  
Negative Impact ◽  
Orthogonal Cutting ◽  
Fluid Simulation ◽  
Cutting Fluid ◽  
Cutting Fluids ◽  
Thermomechanical Effect ◽  
Dimensional Simulation ◽  
On Chip ◽  
Cutting Processes

Abstract Cutting fluids are an important part of today's metal cutting processes, especially when machining aerospace alloys. They offer the possibility to extend tool life and improve cutting performance. However, the equipment and handling of cutting fluids also raises manufacturing costs. To reduce the negative impact of the high cost of cutting fluids, cooling systems and strategies are constantly being optimized. In most existing works, the influences of different cooling strategies on the relevant process parameters, such as tool wear, cutting forces, chip breakage, etc., are empirically investigated. Due to the limitations of experimental methods, analysis and modeling of the working mechanism has so far only been carried out at a relatively abstract level. For a better understanding of the mechanism of cutting fluids, a thermal coupled two-dimensional simulation approach for the orthogonal cutting process was developed in this work. This approach is based on the Coupled Eulerian Lagrangian (CEL) method and provides a detailed investigation of the cutting fluid’s impact on chip formation and tool temperature. For model validation, cutting tests were conducted on a broaching machine. The simulation resolved the fluid behavior in the cutting area and showed the distribution of convective cooling on the tool surface. This work demonstrates the potential of CEL based cutting fluid simulation, but also pointed out the shortcomings of this method.

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