Transformation of Cutting Burr/Fracture in High-Speed Machining Al Alloy

2008 ◽  
Vol 53-54 ◽  
pp. 101-107 ◽  
Author(s):  
Qin Xi Shen ◽  
Gui Cheng Wang ◽  
Yun Ming Zhu ◽  
Hai Jun Qu
Keyword(s):  
High Speed ◽  
Metal Cutting ◽  
Element Model ◽  
Scientific Basis ◽  
Burr Formation ◽  
Cutting Condition ◽  
Al Alloy ◽  
High Speed Machining ◽  
Fracture Formation ◽  
Transformation Condition

The metal cutting burr is one of the factors that influence the edge quality and performance of precision parts.A finite element model has been established to investigate the mechanism of burr formation and limit transformation in high-speed machining 2024Aluminum alloy .The burr/fracture formation process is simulated with elastic-plastic nonlinear element method based on ABAQUS.This paper has investigated the mechanism of burr /fracture formation and the limit transformation condition of cutting-direction burrs and fractures in high-speed machining and the limit transformation condition change with the cutting condition,which lay scientific basis of further research on cutting burrs formation and its minimization and deburring technology.

Finite Element Modeling of Burr Formation in Metal Cutting with a Backup Material

2007 ◽  
Vol 24-25 ◽  
pp. 71-76 ◽  
Author(s):  
Wen Jun Deng ◽  
Wei Xia ◽  
Long Sheng Lu ◽  
Yong Tang
Keyword(s):  
Finite Element ◽  
Finite Element Model ◽  
Material Properties ◽  
Metal Cutting ◽  
Element Model ◽  
Burr Formation ◽  
Tool Geometry ◽  
Cutting Condition ◽  
Burr Size ◽  
Initiation And Propagation

2D finite element model with the same material for backup to minimize the burr size was developed to investigate mechanism of burr formation and burr minimization. The flowstress of the workpiece and backup material are taken as a function of strain, strain-rate and temperature. Temperature-dependent material properties are also considered. The Cockroft-Latham damage criterion has been adopted to simulate ductile fracture. The crack initiation and propagation is simulated by deleting the mesh element. The result shows putting a backup material behind the edge of the workpiece is an effective way to minimize the burr size. The effects of cutting condition, temperature and different backup material properties on the burr formation and burr size can be investigated using the developed finite element model. This model could be useful in the search for optimal tool geometry and cutting condition for burr minimization and for the modeling of a burr formation mechanism.

Finite Element Modeling of Burr Formation in Orthogonal Metal Cutting

2008 ◽  
Vol 53-54 ◽  
pp. 71-76 ◽  
Author(s):  
Wen Jun Deng ◽  
C. Li ◽  
Wei Xia ◽  
X.Z. Wei
Keyword(s):  
Finite Element ◽  
Steady State ◽  
Metal Cutting ◽  
Cutting Tool ◽  
Element Model ◽  
Burr Formation ◽  
Cutting Condition ◽  
Simulation Procedure ◽  
Chip Flow ◽  
Orthogonal Metal Cutting

A coupled thermo-mechanical model of plane-strain orthogonal metal cutting including burr formation is presented using the commercial finite element code. A simulation procedure based on Normalized Cockroft-Latham damage criterion is proposed for the purpose of better understanding the burr formation mechanism and obtaining a quantitative analysis of burrs at exit. The cutting process is simulated from the transient initial chip formation state to the steady-state of cutting, and then to tool exit transient chip flow, by incrementally advancing the cutting tool. The effects of cutting condition on the non-steady-state chip flow while tool exit can be investigated using the developed finite element model.

Thermal Characters of the Air-Cooled High Speed Motorized Spindle for Wood-Working Machine

2013 ◽  
Vol 579-580 ◽  
pp. 568-572
Author(s):  
Da Guo Ma ◽  
Xin Bo Jiang
Keyword(s):  
High Speed ◽  
Metal Cutting ◽  
Heat Dissipation ◽  
Element Model ◽  
Structure Design ◽  
Air Cooling ◽  
Heat Sources ◽  
Motorized Spindle ◽  
Dissipation Structure ◽  
Motorized Spindles

The structure and composition of the air-cooled high speed motorized spindle for wood-working machine and some features relative to the metal cutting motorized spindle are introduced briefly. Then the main heat sources and heat dissipation mechanism of the air-cooled motorized spindle are thoroughly analyzed, finite element model of the air-cooled motorized spindle is built, the motorized spindles temperature distribution under thermal steady state and the influence of speed are analyzed. The results show that air cooling relative to the water or oil cooling has many advantages and reasonable heat dissipation structure design of air-cooled motorized spindle could meet the requirements of the high-speed motorized spindle for wood-working machine.

FEM Simulation of the Residual Stress in the Machined Surface Layer for High-Speed Machining

2006 ◽  
Vol 315-316 ◽  
pp. 140-144 ◽  
Author(s):  
Su Yu Wang ◽  
Xing Ai ◽  
Jun Zhao ◽  
Z.J. Lv
Keyword(s):  
Residual Stress ◽  
Finite Element ◽  
Surface Layer ◽  
Residual Stresses ◽  
High Speed ◽  
Metal Cutting ◽  
Orthogonal Cutting ◽  
High Speed Machining ◽  
Machined Surface ◽  
Cutting Model

An orthogonal cutting model was presented to simulate high-speed machining (HSM) process based on metal cutting theory and finite element method (FEM). The residual stresses in the machined surface layer were obtained with various cutting speeds using finite element simulation. The variations of residual stresses in the cutting direction and beneath the workpiece surface were studied. It is shown that the thermal load produced at higher cutting speed is the primary factor affecting the residual stress in the machined surface layer.

Influences of End Surface Angle of Workpiece on Burr Formation in High Speed Machining

2009 ◽  
Vol 69-70 ◽  
pp. 384-388
Author(s):  
Qin Xi Shen ◽  
Gui Cheng Wang ◽  
Hai Jun Qu ◽  
Yun Ming Zhu
Keyword(s):  
Aluminum Alloy ◽  
Formation Process ◽  
High Speed ◽  
Shear Angle ◽  
Burr Formation ◽  
High Speed Machining ◽  
Formation Processes ◽  
Key Factors ◽  
2024 Aluminum Alloy ◽  
Surface Angle

The end surface angle of workpece is one of key factors that affect burr sizes and shapes. In this paper, the burr formation process of different end surface angle is simulated with elastic plastic nonlinear element method based on ABAQUS. The influence of end surface angle of workpiece on burr formation processes in high-speed machining 2024 Aluminum alloy is analyzed. The influence of end surface angle on burr sizes and shapes is studied based on equivalent shear strain and negative shear angle. The results have investigated the mechanisms of burr formation fundamentally, which is the basis of burr minimization.

Modal Analysis of BT Spindle-Toolholder Interface Based on Abaqus/Standard

2013 ◽  
Vol 662 ◽  
pp. 632-636
Author(s):  
Yong Sheng Zhao ◽  
Jing Yang ◽  
Xiao Lei Song ◽  
Zi Jun Qi
Keyword(s):  
Finite Element ◽  
Finite Element Model ◽  
Modal Analysis ◽  
Dynamic Characteristics ◽  
High Speed ◽  
Element Model ◽  
Contact Theory ◽  
High Speed Machining ◽  
The Finite Element Model

The quality of high speed machining is directly related to dynamic characteristics of spindle-toolholder interface. The paper established normal and tangential interactions of BT spindle-toolholder interface based on finite element contact theory, and analysed free modal in Abaqus/Standard. Then the result was compared with the experimental modal analysis. It shows that the finite element model is effective and could be applied in the future dynamic study of high-speed spindle system.

scholarly journals MATING SURFACES MACHINING IN CROSSED CHANNELS

2020 ◽  
Vol 2020 (3) ◽  
pp. 4-10
Author(s):  
Oleg Kirillov ◽  
Vladislav Smolencev ◽  
Evgeniy Kotukov
Keyword(s):  
Electric Field ◽  
High Speed ◽  
Metal Cutting ◽  
Working Environment ◽  
Mathematical Statistics ◽  
Work Piece ◽  
High Speed Machining ◽  
Mathematical Apparatus ◽  
Cutting Equipment ◽  
Selection Of

The purpose of the work is the application of a non-profiled electrode-brush for mating surfaces machining including that in crossed channels. To achieve the goal set there were problems under solution: the development of essential equipment, electrode-tools, the selection of working environment, the optimization of combined machining modes. To solve the problems set there are used basis regulations of the theory: electric and combined methods of machining, the mathematical apparatus of probability theories and mathematical statistics. In the paper the developed and manufactured plants and electrode-tools are shown. The recommended machining conditions, working environment are shown. The equipment is presented with a small-size plant for high-speed machining with an electrode-brush and a portable plant fixed on a drill rod that with the use of operating fluid recommended allows reducing considerably the terms and cost of metal cutting equipment updating for machining with electric field imposition. In the paper there are considered standard parts: nozzles, ejector bodies, parts of piping hydro-systems. The results of machining parts with crossed channels are shown. The application of processing by an electrode-brush with high circumferential velocities with regard to the work-piece from 35 m/sec and higher allows manufacturing products with the set values. The application of an electrode-brush is efficient for mating surfaces combined machining.

Finite Element Modeling and Experimental Study of Burr Formation in Drilling Processes

2016 ◽  
Author(s):  
Chara Efstathiou ◽  
Dimitrios Vakondios ◽  
Antonios Lyronis ◽  
Konstantinos Sofiakis ◽  
Aristomenis Antoniadis
Keyword(s):  
Experimental Study ◽  
Finite Element ◽  
High Speed ◽  
Cutting Speed ◽  
Element Model ◽  
Burr Formation ◽  
Manufacturing Processes ◽  
Manufacturing Cost ◽  
High Speed Camera ◽  
Exit Surface

Drilling is among the most significant manufacturing processes since it is widely used in the production of almost any product or part. Research in drilling processes and investigation of the phenomena that occur during the process is of great interest, given the fact that drilling is mainly applied at the final stages of the production process, thus it can greatly affect the total manufacturing cost. In the context of this study, a finite element model to simulate drilling and burr formation both on entrance and exit surface of the workpiece, was created. Simulation was implemented for the investigation of several combinations of cutting conditions, namely cutting speed and feed rate and the model was validated with a series of drilling experiments monitored by a high-speed camera.

Chip Formation in High-Speed Cutting of Copper and Aluminum

1963 ◽  
Vol 85 (4) ◽  
pp. 365-372 ◽  
Author(s):  
K. J. Trigger ◽  
B. F. von Turkovich
Keyword(s):  
Plastic Deformation ◽  
Chip Formation ◽  
High Speed ◽  
Metal Cutting ◽  
Initial Temperature ◽  
High Speed Machining ◽  
High Speed Cutting ◽  
Work Material ◽  
On Chip ◽  
Cutting Behavior

This paper presents metal-cutting data for the high-speed machining of copper and aluminum, each at two levels of purity, and over a range of workpiece temperatures from −326 deg F (80 deg K) to 550 deg F (560 deg K). It has been found that cutting behavior is influenced by purity of work material, its initial temperature, and extent of tool-chip contact. The influence of plastic deformation on chip hardness has been found to be intimately associated with the purity of the work material.

Finite Element Modelling and Analysis of Cutting-Direction Burr Formation

2008 ◽  
Vol 392-394 ◽  
pp. 88-92
Author(s):  
Xiao Wang ◽  
H. Yan ◽  
C. Liang ◽  
B. Wu ◽  
Hui Xia Liu ◽  
...  
Keyword(s):  
Finite Element ◽  
Finite Element Model ◽  
Metal Cutting ◽  
Chip Thickness ◽  
Element Model ◽  
Rake Angle ◽  
Burr Formation ◽  
Workpiece Material ◽  
Orthogonal Machining ◽  
Cutting Direction

To prevent or reduce the formation of burr efficiently in metal cutting, it is necessary to reveal the burr formation mechanism. A finite element model of cutting-direction burr formation in orthogonal machining was presented in this paper. The simulation of the burr formation process was conducted. Undeformed chip thickness, rake angle, rounded cutting edge radius and workpiece material were included in cutting conditions, whose influences on burr formation were investigated, according to the simulation results. By comparing the results of the simulation and the experiment, good consistency is achieved which proves that the finite element model of burr formation in this paper is significant and effective to predict burr formation.

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