3D Finite Element Modeling of the Machining of Ti6Al4V Alloys

2011 ◽  
Vol 189-193 ◽  
pp. 1926-1929 ◽  
Author(s):  
Ji Hong Yang ◽  
Shou Jin Sun ◽  
Milan Brandt ◽  
Wen Yi Yan
Keyword(s):  
Finite Element ◽  
Chip Formation ◽  
Element Model ◽  
Cutting Process ◽  
Temperature Fields ◽  
Contact Friction ◽  
Dynamic Effects ◽  
3D Finite Element ◽  
Mechanical Coupling ◽  
Damage Law

A 3D finite element model of the machining of Ti6Al4V alloy has been developed. This model is able to simulate the formation of continuous or discontinuous chips during the cutting process that depends on the cutting conditions. In this model, the yield stress is considered as a function of the strain, the strain rate and the temperature. The dynamic effects, thermo-mechanical coupling, constitutive damage law and contact friction are taken into account. The stresses and temperature fields, chip formation and tool forces are obtained at different stages of the cutting process.

3D Finite Element Simulation of Cutting Process Using Surface Micro-Textured Cutting Tool

2014 ◽  
Vol 1049-1050 ◽  
pp. 949-952
Author(s):  
Hao Kai Yang ◽  
Yu Yang Tu
Keyword(s):  
Finite Element ◽  
Metal Cutting ◽  
Surface Texturing ◽  
Element Model ◽  
Cutting Process ◽  
Laser Surface Texturing ◽  
Machining Processes ◽  
3D Finite Element ◽  
Interface Surface ◽  
Micro Dimples

Surface texturing has become a technique to reduce friction and wear in cutting process; laser surface texturing is a method used to create micro-dimples on the interface surface. It is considered that cutting of titanium is difficult. As the experiments are costly and time demanding, metal cutting modeling provides an alternative way for better understanding of machining processes under different cutting conditions. In this paper a 3D finite element model has been used to simulate the cutting process of titanium alloy Ti6Al4V to predict the cutting forces and temperatures.

scholarly journals Influences of Cutting Speed and Material Constitutive Models on Chip Formation and their Effects on the Results of Ti6Al4V Orthogonal Cutting Simulation

2021 ◽  
Author(s):  
Nithyaraaj Kugalur-Palanisamy ◽  
Edouard Rivière-Lorphèvre ◽  
Pedro-José Arrazola ◽  
François Ducobu
Keyword(s):  
Finite Element ◽  
Constitutive Model ◽  
Chip Formation ◽  
Orthogonal Cutting ◽  
Constitutive Models ◽  
Cutting Speed ◽  
Element Model ◽  
Cutting Process ◽  
Machine Material ◽  
On Chip

The highly used Ti6Al4V alloy is a well know hard-to-machine material. The modelling of orthogonal cutting process of Ti6Al4V attract the interest of many researchers as it often generates serrated chips. The purpose of this paper is to show the significant influence of cutting speed on chip formation during orthogonal cutting of Ti6Al4V along with different material constitutive models. Finite element analyses for chip formation are conducted for different cutting speeds and are investigated with well-known Johnson-Cook constitutive model, a modified Johnson–Cook model known as Hyperbolic Tangent (TANH) model that emphasizes the strain softening behavior and modified Johnson-Cook constitutive model that consider temperature dependent strain hardening factor. A 2D Lagrangian finite element model is adopted for the simulation of the orthogonal cutting process and the results from the simulations such as calculated forces, chip morphologies are analyzed and are compared with the experimental results to highlight the differences. The results analysis shows that, the temperature in the secondary deformation zone is directly proportional to the cutting speed.

Finite Element Analysis of the Influence of the Material Constitutive Law Formulation on the Chip Formation Process During a High Speed Metal Cutting

2012 ◽  
Author(s):  
Adinel Gavrus ◽  
Pascal Caestecker ◽  
Eric Ragneau
Keyword(s):  
Finite Element ◽  
Formation Process ◽  
Chip Formation ◽  
High Speed ◽  
Metal Cutting ◽  
Orthogonal Cutting ◽  
Constitutive Law ◽  
Cutting Process ◽  
Contact Friction ◽  
Numerical Predictions

During the last decades, the importance of machining in manufacturing industry has required rigorous scientific studies concerning the chip formation process in order to determine optimal speeds, feeds or other technological parameters. For all types of machining including turning, milling, grinding, honing or lapping, the phenomenon of chip formation is similar in terms of the local interaction between the tool and the work piece. Because of the intensive use of CNC machine tools producing parts at ever-faster rates, it has become important to provide analysis of high speed cutting where complex loading conditions occur during the fabrication process: high gradients of the thermo-mechanical variables, strong nonlinearities of the thermo-mechanical coupling, large plastic strains, extremely high strain rates compared to that of other forming processes, important influence of the contact friction and of the microstructure evolution. Today many scientific researches are focalized on finite element analyses of the chip formation and of its morphology evolution during a high speed metals cutting process. To improve the quality of the numerical predictions, a better description of the local shear band formation is needed, using adequate rheological models. On this point of view this paper deals with the influence of the rheological behavior formulation on the morphology and geometry of the chip formation during a finite element simulation of a high speed metal cutting process. Numerical simulations of a high speed orthogonal cutting of special steels are employed to analysis the sensitivity of the numerical results describing the local cutting area with respect to different rheological laws: Norton-Hoff or Cowper-Symonds model, Johnson-Cook one or Zerilli-Armstrong formulation. To obtain a better description of the local material loadings and to take into account the important gradient of the strain rate, plastic strain and temperature values, a more adequate constitutive model is proposed by the author.

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 3D finite element model of dynamic material behaviors for multilayer ultrasonic metal welding

2021 ◽  
Vol 62 ◽  
pp. 302-312
Author(s):  
Ninggang Shen ◽  
Avik Samanta ◽  
Wayne W. Cai ◽  
Teresa Rinker ◽  
Blair Carlson ◽  
...  
Keyword(s):  
Finite Element ◽  
Finite Element Model ◽  
Element Model ◽  
3D Finite Element ◽  
Ultrasonic Metal Welding ◽  
3D Finite Element Model ◽  
Material Behaviors ◽  
Metal Welding

scholarly journals A Novel, Improved Equivalent Circuit Model for Double-Sided Linear Induction Motor

Electronics ◽  
2021 ◽  
Vol 10 (14) ◽  
pp. 1644
Author(s):  
Qian Zhang ◽  
Huijuan Liu ◽  
Tengfei Song ◽  
Zhenyang Zhang
Keyword(s):  
Finite Element ◽  
Finite Element Model ◽  
Equivalent Circuit ◽  
Skin Effect ◽  
Equivalent Circuit Model ◽  
Element Model ◽  
Circuit Model ◽  
End Effects ◽  
3D Finite Element ◽  
Linear Induction

A novel, improved equivalent circuit model of double-sided linear induction motors (DLIMs) is proposed, which takes the skin effect and the nonzero leakage reactance of the secondary, longitudinal, and transverse end effects into consideration. Firstly, the traditional equivalent circuit with longitudinal and transverse end effects are briefly reviewed. Additionally, the correction coefficients for longitudinal and transverse end effects derived by one-dimensional analysis models are given. Secondly, correction factors for skin effect, which reflects the inhomogeneous air gap magnetic field vertically, and the secondary leakage reactance are derived by the quasi-two-dimensional analysis model. Then, the proposed equivalent circuit is presented, and the excitation reactance and secondary resistance are modified by the correction coefficients derived from the three analytical models. Finally, a three-dimensional (3D) finite element model is used to verify the proposed equivalent circuit model under varying air gap width and frequency, and the results are also compared with that of the traditional equivalent circuit models. The calculated thrust characteristics by the proposed equivalent circuit and 3D finite element model are experimentally validated under a constant voltage–frequency drive.

Study on the Deformation of the Oil-Immersed Transformer Tank by FEA

2011 ◽  
Vol 422 ◽  
pp. 51-54 ◽  
Author(s):  
Jian Hua Zhang ◽  
Ling Yu Sun ◽  
Xiao Jun Zhang ◽  
Jia Peng Li
Keyword(s):  
Finite Element ◽  
Finite Element Model ◽  
Mechanical Strength ◽  
Element Model ◽  
3D Finite Element ◽  
3D Finite Element Model ◽  
Series Of Experiments ◽  
Oil Tank ◽  
Directive Function

The oil-immersed transformer tank is an outside package component of the transformer body. The sealing quality and mechanical strength of the oil tank are affected by the deformation after loading. In this paper, the 3D finite element model of oil-immersed transformer tank is established. The oil-immersed transformer tank deformation is obtained by FEA under the condition of vacuuming. A series of experiments about the deformation of the oil-immersed transformer tank are carried out. Comparing experiment results with FEA results, FEA results are agrees well with the experiments’. It can save the time consumed on designing the oil tank, and has the directive function for the whole design.

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