Tool Load during Multi-Flank Chip Formation

2011 ◽  
Vol 223 ◽  
pp. 525-534 ◽  
Author(s):  
Fritz Klocke ◽  
Christof Gorgels ◽  
Stefan Herzhoff
Keyword(s):  
Chip Formation ◽  
Mechanical Load ◽  
Bevel Gear ◽  
Cutting Edge ◽  
Machining Simulation ◽  
Gear Cutting ◽  
Gear Hobbing ◽  
Simulation Results ◽  
Cutting Processes ◽  
Mechanical Tool

Tools used in cutting processes with multi-flank chip formation like gear hobbing or bevel gear cutting, often reach their tool life due to excessive wear at the tool corner radius. Tool wear depends on the strength of the cutting edge and on the thermal and mechanical load. The objective of this work is to analyze the thermal and mechanical tool load during multi-flank chip formation. As the tool load cannot be measured in the necessary high local resolution, a finite element based machining simulation is used to model the process of chip formation. The simulation is able to calculate the temperature and stress distribution along the cutting edge. For the examinations presented in this report the bevel gear cutting process for ring gears is simulated. The simulation results show a significant thermal and mechanical load maximum at the tool corner, where the maximal wear occurs in cutting.

Failure Analysis of Engine Valves and its Performance Evaluation under Various Titanium Based Composite Coatings Using FE Analysis

2021 ◽  
Vol 903 ◽  
pp. 79-89
Author(s):  
R. Sundara Rao ◽  
K. Hemachandra Reddy ◽  
Ch.R. Vikram Kumar
Keyword(s):  
Finite Element ◽  
High Temperature ◽  
Combustion Engine ◽  
Mechanical Load ◽  
Composite Coatings ◽  
Surface Hardness ◽  
Engine Operation ◽  
Engine Valve ◽  
Simulation Results ◽  
Two Wheeler

In an internal combustion engine poppet valve is the crucial component which often opens and closes, thereby regulating gas flow in an engine cylinder. During engine operation, the valve is exposed to high temperature gases (thermal load) along with spring and cam loads (mechanical load). Due to high temperatures and fatigue loads, the valves are subjected to metallurgical changes and leads to failure. In order to resist these extreme conditions of high temperature and mechanical loads, the engine valve should possess special properties such as high surface hardness, a good amount of thermal conductivity, and fatigue strength. In this work, the reasons for the failure of two wheeler engine valve were evaluated and found that failure takes place due to change in the chemical composition mainly due to thermal diffusion at the interfaces. Thermal barrier coatings on the valve surface arrest the temperature load and increase its life. In this work, the performance of various titanium based composite coatings, i.e., TiN, TiC, TiC-Al2O3, TiCN, TiAlN, TiN- Al2O3, DLC, and uncoated valves of two wheeler engine was simulated using Finite Element Analysis. The simulation results indicated that coated valves have less thermal and fatigue loading and have more life than the uncoated valve. The Finite element simulation results of both coated and uncoated valves are presented and analyzed in this paper.

scholarly journals Chip Formation and Exit Failure of Cutting Edge (2nd Report)

1990 ◽  
Vol 56 (5) ◽  
pp. 911-916 ◽  
Author(s):  
Eiji USUI ◽  
Toshiyuki OBIKAWA ◽  
Takashi MATSUMURA
Keyword(s):  
Chip Formation ◽  
Cutting Edge

Development of Three-Dimensional Parametric Modeling for Milling Process Simulation

2010 ◽  
Vol 139-141 ◽  
pp. 1178-1183
Author(s):  
Jing Sheng ◽  
Guang Guo Zhang ◽  
Hong Hua Zhang
Keyword(s):  
3D Modeling ◽  
Process Simulation ◽  
Three Dimensional ◽  
Milling Process ◽  
Parametric Modeling ◽  
Machining Simulation ◽  
Metal Machining ◽  
Simulation Results ◽  
Key Techniques ◽  
Access Data

Metal machining simulation using finite element method (FEM) is extraordinarily complex. It is essential to develop a system so as to construct simulation model and obtain valuable results conveniently and rapidly. This study developed a parametric modeling based on MSC.Marc software, which included the key techniques of three-dimensional (3D) modeling and the parametric modeling course of metal milling process. In addition, an explanation facility based on the procedure file, which could be run automatically, was performed according to a modeling procedure. The interface of the system designed using Builder, could access data, which included the geometric angles and the dimensions of a tool and a workpiece, the relative position between them, their properties and cutting conditions, etc.. Calling the procedure file, the system approached the parametric modeling. An example was given, which simulation results indicated that it is an effective methodology to develop 3D parametric modeling.

Manufacture of face-hobbed straight bevel gears using a six-axis CNC bevel gear cutting machine

2013 ◽  
Vol 68 (9-12) ◽  
pp. 2499-2515 ◽  
Author(s):  
Yi-Pei Shih ◽  
Ya-Chuan Huang ◽  
Yi-Hui Lee ◽  
Jhih-Ming Wu
Keyword(s):  
Bevel Gear ◽  
Bevel Gears ◽  
Gear Cutting ◽  
Cutting Machine

Investigation of the Hertzian Stress Distribution on the Surface of the Straight Bevel Gear

2013 ◽  
Vol 307 ◽  
pp. 304-307 ◽  
Author(s):  
Aref Bahramighahnavieh ◽  
Peiman Mosaddegh ◽  
Saleh Akbarzadeh
Keyword(s):  
Stress Distribution ◽  
Spur Gear ◽  
Bevel Gear ◽  
Gear Teeth ◽  
Straight Bevel Gear ◽  
Face Width ◽  
The Face ◽  
Simulation Results ◽  
Abaqus Software ◽  
Good Agreement

In this paper, a model has been developed for calculating the Hertzian stress distribution of straight bevel gear. One pair of straight bevel gear teeth replaced with multiple pairs of spur gear teeth by using Tredgold approximation. The transmitted load and radii of curvature are evaluated and used to determine the stress distribution. The results show that these stresses are constant along the face width of tooth. Moreover, the magnitude of theses stresses are in good agreement with the simulation results using commercial ABAQUS software

scholarly journals Machinability of Stone—Plastic Materials During Diamond Planing

2019 ◽  
Vol 9 (7) ◽  
pp. 1373 ◽  
Author(s):  
Zhaolong Zhu ◽  
Dietrich Buck ◽  
Xiaolei Guo ◽  
Pingxiang Cao ◽  
Mats Ekevad
Keyword(s):  
Chip Formation ◽  
Orthogonal Cutting ◽  
Cutting Edge ◽  
Cutting Depth ◽  
Normal Forces ◽  
Plastic Composite ◽  
Chip Shape ◽  
Plastic Materials ◽  
Cutting Heat ◽  
Von Mises

This paper investigated the machinability of a stone–plastic composite (SPC) via orthogonal cutting with diamond cutters. The objective was to determine the effect of cutting depth on its machinability, including cutting forces, heat, chip formation, and cutting quality. Increased cutting depth promoted an increase in both frictional and normal forces, and also had a strong influence on the change in normal force. The cutting temperatures of chips and tool edges showed an increasing trend as cutting depth increased. However, the cutting heat was primarily absorbed by chips, with the balance accumulating in the cutting edge. During chip formation, the highest von Mises strain was mainly found in SPC ahead of the cutting edge, and the SPC to be removed partially passed its elastic limit, eventually forming chips with different shapes. Furthermore, the average surface roughness and the mean peak-to-valley height of machined surfaces all positively correlated to an increase in cutting depth. Finally, with an increase in cutting depth, the chip shape changed from tubular, to ribbon, to arc, to segmental, and finally, to helical chips. This evolution in chip shape reduced the fluctuation in cutting force, improving cutting stability and cutting quality.

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