Formation of Cutting Direction Burr/Fracture in Orthogonal Cutting

2012 ◽  
Vol 426 ◽  
pp. 73-76 ◽  
Author(s):  
Hai Jun Qu ◽  
Gui Cheng Wang ◽  
Y.M Zhu ◽  
Q.X Shen
Keyword(s):  
Mechanical Properties ◽  
Orthogonal Cutting ◽  
Element Model ◽  
Material Failure ◽  
Forming Process ◽  
Fracture Formation ◽  
Edge Quality ◽  
Simulation Results ◽  
And Performance ◽  
Cutting Direction

Cutting direction burr/fracture is one of the important factors that influence the edge quality and performance of precision parts. A finite element model based on material failure mode is developed in this study to simulate the burr /fracture forming process. According to workpiece materials deformation and mechanical properties from the simulation results, the cutting direction burr/fracture formation process is analyzed. The cutting direction burr forms when there is a crack in the area near the tool tip and grow along the principal shear zone, the cutting direction fracture forms as the crack grow along negative zone.

Formation and Simulation of Cutting-Direction Burr in Orthogonal Cutting

2007 ◽  
Vol 24-25 ◽  
pp. 249-254 ◽  
Author(s):  
Hai Jun Qu ◽  
Gui Cheng Wang ◽  
Hong Jie Pei ◽  
Qin Feng Li ◽  
Yun Ming Zhu
Keyword(s):  
Shear Zone ◽  
Formation Process ◽  
Orthogonal Cutting ◽  
Shear Angle ◽  
Burr Formation ◽  
Size And Shape ◽  
Study Results ◽  
Edge Quality ◽  
And Performance ◽  
Cutting Direction

The cutting-direction burr is one of the important factors that influence the edge quality and performance of precision parts. The cutting-direction burr formation process is simulated with DeformTH3D. The mechanism of cutting-direction burr formation is analyzed in terms of the results of the simulation. The negative shear zone and initiation negative shear angle are discussed too. Study results show that the deformation of CDE is an important factor affect the cutting direction burrs’ size and shape.

The Effect of Shear Strain on Transformation between Burr and Negative Burr

2008 ◽  
Vol 53-54 ◽  
pp. 89-93
Author(s):  
Yun Ming Zhu ◽  
Gui Cheng Wang ◽  
Qin Xi Shen ◽  
Hai Jun Qu ◽  
Hong Jie Pei
Keyword(s):  
Shear Strain ◽  
Element Model ◽  
Critical Value ◽  
Burr Formation ◽  
Forming Process ◽  
Edge Quality ◽  
Simulation Results ◽  
Machining Operations ◽  
The Finite Element Model

In most machining operations undersirable burr or negative burr is created at workpiece edges. The burr/negative burr formation mechanism is analyzed based on shear strain which is obtained from simulation results of the finite element model of burr/negative burr forming process. To varify the simulation results, experiments are conducted. We observered that there exists a critical value of shear strain for burr/negative burr transformation. Burr or negative burr, which to be formed at workpiece edges can be controlled by adjusting the cutting conditions or tool geometric parameters. Edge quality of workpiece can be controlled by converting burr or negative burr forming.

Formation and Simulation of Negative Shear Zone

2014 ◽  
Vol 1027 ◽  
pp. 217-220
Author(s):  
Hai Jun Qu ◽  
J.H. Yang ◽  
Gui Cheng Wang
Keyword(s):  
Finite Element ◽  
Shear Zone ◽  
Element Model ◽  
Nonlinear Finite Element Method ◽  
Rigid Plastic ◽  
Zone Formation ◽  
Edge Quality ◽  
And Performance ◽  
Cutting Direction

Cutting-direction burr/fracture is one of the important factors that influence the edge quality and performance of precision parts.The formation of negative shear zone decisions the edge quality of workpiece. A finite element model has been established to investigate the mechanism of negative formation in machining H64 brass. The negative shear zone formation process is simulated with rigid-plastic nonlinear finite element method. The cutting direction burr forms when the stress of principal shear zone great than it in negative, the cutting direction fracture forms when the stress of principal shear zone less than it in negative and there is a crack in the area near the tool tip and grow along the negative shear zone .

The Analysis of Fracture Formation on Exit Edge in Pricision Machining

2010 ◽  
Vol 135 ◽  
pp. 174-178 ◽  
Author(s):  
Gui Cheng Wang ◽  
Qin Xi Shen ◽  
Yun Ming Zhu
Keyword(s):  
Shear Strain ◽  
Formation Process ◽  
Element Model ◽  
Machining Process ◽  
Forming Process ◽  
Fracture Formation ◽  
Simulation Results ◽  
Exit Edge

Burrs and fractures are two types of shapes formed on exit edges in pricision machining. They affect the quality of workpiece and the efficiency of prodcution seriously. A finite element model of fracture formation process to simulate the machining process of 2024-T3 Aluminum alloy is proposed. According to simulation results, five stages and variation of shear shain in fracture formation process are analyzed. It is found that shear strain plays an important role in fracture forming process. The method of determination of critical shear strain for fracture forming is proposed from simulation results.

Analyze on the Mechanical Properties of Stitched Composites

2011 ◽  
Vol 217-218 ◽  
pp. 1758-1762
Author(s):  
Tao Chang
Keyword(s):  
Mechanical Properties ◽  
Finite Element ◽  
Low Cost ◽  
Element Model ◽  
Textile Composites ◽  
External Loading ◽  
Engineering Practice ◽  
Textile Composite ◽  
And Performance ◽  
Potential Member

As the most potential member in the textile composite material, stitched textile composites have already been paid a lot attention. By the simply technology form and relatively low cost, stitched composites had attracted many domestic and foreign researchers, and were gradually used in various engineering practice. This paper using 3D micro-finite element method researches the mechanical behavior and performance of stitched composites, establishing a 3D micro-finite element model for the stitched composites under the improved locking suture way. Through analysis, it shows that each material’s stress distribution characteristics under external loading and finds that the results of this paper’s finite element data results matching well with previous studies’ results, proving the feasibility of this study, so it can be used for forecasting the mechanical properties of a variety of practical stitched composites.

Effect of Dies Temperature on Mechanical Properties of Hot Stamping Square-Cup Part for Ultra High Strength Steel

2010 ◽  
Vol 129-131 ◽  
pp. 390-394
Author(s):  
Cheng Xi Lei ◽  
Zhong Wen Xing ◽  
Hong Ya Fu
Keyword(s):  
Mechanical Properties ◽  
Numerical Simulation ◽  
Hot Stamping ◽  
High Strength ◽  
Hot Forming ◽  
Forming Process ◽  
Stamping Process ◽  
Ultra High Strength Steel ◽  
Mechanical Properties Testing ◽  
Simulation Results

The numerical simulation of hot-stamping process was carried out for UHSS square-cup parts, and the influence of dies temperature on the hot-stamping process was anlysised. Besides, through the microstructure analysis and mechanical properties testing of the formed parts, effects of dies temperature on microstructures and mechanical properties of hot-stamping square-cup parts were obtained. The experiment and simulation results showed that the mechanical properties of the UHSS are strongly dependent on the temperature, so the dies temperature is one of the most important parameters that have to be taken into account in designing the hot-forming dies and the hot-forming process.

scholarly journals Investigation on precision and performance for hot gas forming of thin-walled components of Ti2AlNb-based alloy

2018 ◽  
Vol 190 ◽  
pp. 07001
Author(s):  
Xueyan Jiao ◽  
Zhiqiang Liu ◽  
Yong Wu ◽  
Gang Liu
Keyword(s):  
Process Parameters ◽  
Microstructure Evolution ◽  
Element Model ◽  
Parameters Optimization ◽  
Forming Process ◽  
Performance Control ◽  
Hot Gas ◽  
Thin Walled ◽  
And Performance ◽  
Hot Gas Forming

Ti2AlNb-based alloys have received considerable attention as potential materials to replace the nickel alloy at 600-750 °C, depending on their advantages of high specific strength, good corrosion and oxidation resistance. To realize the precision and performance control for Ti2AlNb-based alloy thin-walled components, the microstructure evolution was analyzed for setting up the unified viscoplastic constitutive equations based on the physical variables and simulating the forming process coupled between the deformation and the microstructure evolution. Through the finite element model with coupling of microstructure and mechanical parameters, the microstructure evolution and shape fabricating can be predicted at the same time, to provide the basis for the process parameters optimization and performance control. With the reasonable process parameters for hot gas forming of Ti2AlNb thin-walled components, the forming precision and performance can be controlled effectively.

FE Simulation of Metal Orthogonal Cutting Processes Based on 3D Adaptive Remeshing Procedure

2011 ◽  
Vol 409 ◽  
pp. 461-466
Author(s):  
Jie Zhang ◽  
Abel Cherouat ◽  
Houman Borouchaki
Keyword(s):  
Complex Geometry ◽  
Orthogonal Cutting ◽  
Element Model ◽  
Forming Process ◽  
Element Mesh ◽  
Adaptive Remeshing ◽  
Nite Element ◽  
Explicit Solver ◽  
Cutting Processes ◽  
Cutting Speeds

Metal orthogonal cutting process involves complex geometry deformation and mate-rial characteristics as large thermal-visco-plastic ow include ductile damage. Simultaneously,the contact with friction occurs in the same zone. To build the nite element model for metalcutting, the nite element mesh will be severely distorted at the region with high gradientof stress/strain/temperature eld. In this paper, a Adaptive remeshing procedure which inte-grates the 3D OPTIFORM mesher, ABAQUS/Explicit solver and eld node-node eld transferalgorithm are proposed to solve these problems. The thermal-mechanical simulation for metalorthogonal cutting is realized to demonstrate our numerical simulation approach. Some simu-lation results are illustrated include continuous chip forming process, thermal-mechanical elddistribution and cutting force in di erent rank angles, cutting speeds and friction conditions.

scholarly journals Study on the Battery Safety in Frontal Collision of Electric Vehicle

2021 ◽  
Vol 2137 (1) ◽  
pp. 012008
Author(s):  
Weigao Qiao ◽  
Lei Yu ◽  
Zhanxi Zhang ◽  
Tongyu Pan
Keyword(s):  
Mechanical Properties ◽  
Finite Element ◽  
Electric Vehicle ◽  
Rapid Development ◽  
Element Model ◽  
Maximum Deformation ◽  
Finite Element Software ◽  
Frontal Collision ◽  
Simulation Results ◽  
Test Requirements

Abstract With the rapid development of electric vehicle industry, more and more attention has been paid to the safety of the automotive battery. The safety of battery in electric vehicle’s frontal collision is the focus of this paper. In the process of simulated collision, the research object is simplified into a battery box. The mechanical properties of the battery monomers were investigated to summarize the mechanical properties of the internal failure of the monomers. Constructing the finite element model of the research object, we focus on the analysis of collision simulation results and propose the improvement measures. According to the test requirements in C-NCAP, the crash simulation of battery box is carried out by using the finite element software called LS-DYNA, which is used in automobile collision to analyze the deformation, stress of the battery box and the most dangerous battery monomer during the frontal collision. The simulation results show that the deformation of the case is obvious, and the protection of the battery is lost in the 50km/h frontal collision condition. By adding EVA foam, the maximum deformation of the battery monomer is reduced by 8.2%. By improving the material of battery case, the maximum deformation is reduced by 12.65%.

Effect of different lapping orders on mechanical performance and nugget forming process for three-sheet dissimilar resistance spot welding joints between DC06 and unequal-thickness hot-stamped B1500HS steel sheets

2021 ◽  
Vol 118 (1) ◽  
pp. 112
Author(s):  
Xin Mao ◽  
Zhi Cheng ◽  
Qiang Zhu ◽  
Wurong Wang ◽  
Xicheng Wei ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Formation Mechanism ◽  
Mechanical Performance ◽  
Peak Load ◽  
Element Model ◽  
Type I ◽  
Type Ii ◽  
Forming Process ◽  
Pull Out ◽  
Nugget Formation

In this study, the mechanical properties of two welded joints under different lapping orders (B1500HS-1.4 mm/B1500HS-1.6 mm/DC06, denoted as type I; B1500HS-1.4 mm/DC06/B1500HS-1.6 mm, denoted type II) were compared. The nugget formation mechanism was analysed by a coupled electrical-thermal finite element model (FEM). It is found that different lapping orders significantly affect the mechanical properties of three-sheet RSW joints. All RSW joints tend to fail in the pull-out or tearing failure mode. The peak load of the two interfaces of type II RSW joint is more balanced, and the failure load of which is much higher than that of the type I RSW joint; The warpage was observed at type I welded joint. Considered the load-carrying capacity, type II was excellent. The simulation results indicate that the diameter of the weld nugget at the upper interface of the type I RSW joint was larger than that on the other interfaces, which agree well with the experimental results. The nugget formation mechanism of dissimilar high strength steel three-sheet RSW joint was obtained that forming the nugget firstly from two interfaces and final formed nuggets were asymmetric.

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