Finite Element Model and Analysis for Micro-Cutting of Aluminum Alloy 7050-T7451

2012 ◽  
Vol 566 ◽  
pp. 650-653 ◽  
Author(s):  
Fu Zeng Wang ◽  
Jie Sun ◽  
Pei Qin Sun ◽  
Jun Zhou
Keyword(s):  
Finite Element ◽  
Finite Element Model ◽  
Cutting Force ◽  
Chip Thickness ◽  
Element Model ◽  
Actual State ◽  
Depth Of Cut ◽  
Fe Model ◽  
Uncut Chip Thickness ◽  
Micro Cutting

In this paper, a finite element model with respect to actual state of micro-cutting is established by adopting software of ABAQUS/Explicit. Based on the FE model, the cutting force and specific cutting force with various uncut depth of cut with different cutting edge radius are compared and then analyzed with regard to this simulation. In micro-cutting, the nonlinear scaling phenomenon is more evident with the decreasing of uncut chip thickness. The likely explanations for the size effect in small uncut chip thickness are discussed in this paper.

Evidence of Ductile Tearing Ahead of the Cutting Tool and Modeling the Energy Consumed in Material Separation in Micro-Cutting

2006 ◽  
Vol 129 (2) ◽  
pp. 321-331 ◽  
Author(s):  
Sathyan Subbiah ◽  
Shreyes N. Melkote
Keyword(s):  
Finite Element ◽  
Finite Element Model ◽  
Damage Model ◽  
Chip Thickness ◽  
Element Model ◽  
Uncut Chip Thickness ◽  
Micro Cutting ◽  
Ductile Tearing ◽  
Material Separation ◽  
Cutting Experiments

Orthogonal cutting experiments using a quick-stop device are performed on Al2024-T3 and OFHC copper to study the chip–workpiece interface in a scanning electron microscope. Evidence of ductile tearing ahead of the tool at cutting speeds of 150m∕min has been found. A numerical finite element model is then developed to study the energy consumed in material separation in micro-cutting. The ductile fracture of Al2024-T3 in a complex stress state ahead of the tool is captured using a damage model. Chip formation is simulated via the use of a sacrificial layer and sequential elemental deletion in this layer. Element deletion is enforced when the accumulated damage exceeds a predetermined value. A Johnson–Cook damage model that is load history dependent and with strain-to-fracture dependent on stress, strain rate, and temperature is used to model the damage. The finite element model is validated using the cutting forces obtained from orthogonal micro-cutting experiments. Simulations are performed over a range of uncut chip thickness values. It is found that at lower uncut chip thickness values, the percentage of energy expended in material separation is higher than at higher uncut chip thicknesses. This work highlights the importance of the energy associated with material separation in the nonlinear scaling effect of specific cutting energy in micro-cutting.

Evidence of Ductile Tearing Ahead of the Cutting Tool and Modeling the Energy Consumed in Material Separation in Micro-Cutting

2006 ◽  
Author(s):  
Sathyan Subbiah ◽  
Shreyes Melkote ◽  
Udaykumar A. Dabade ◽  
Nitin Banait ◽  
Suhas S. Joshi
Keyword(s):  
Finite Element ◽  
Finite Element Model ◽  
Damage Model ◽  
Chip Thickness ◽  
Element Model ◽  
Uncut Chip Thickness ◽  
Micro Cutting ◽  
Ductile Tearing ◽  
Material Separation ◽  
Cutting Experiments

Orthogonal micro-cutting experiments using quick-stop device are performed on Al2024-T3 and OFHC Copper to study the chip-workpiece interface in a SEM. Evidence of ductile tearing ahead of the tool at cutting speeds of 150 m/min has been found. A numerical finite element model is then developed to study the energy consumed in material separation in micro-cutting. The ductile fracture of Al2024-T3 in a complex stress state ahead of the tool is captured using a damage model. Chip formation is simulated via use of a sacrificial layer and sequential elemental deletion in this layer. Element deletion is enforced when the accumulated damage exceeds a predetermined value. A Johnson-Cook damage model that is load history dependent and with strain-to-fracture dependent on stress, strain-rate, and temperature is used to model the damage. The finite element model is validated using the cutting forces obtained from orthogonal micro-cutting experiments. Simulations are performed over a range of uncut chip thickness values. It is found that at lower uncut chip thickness values, the percentage of energy expended in material separation is higher than at higher uncut chip thicknesses. This work highlights the importance of the energy associated with material separation in the non-linear scaling effect of specific cutting energy in micro-cutting.

Simulation and Study on the Formation Mechanism of Chip Based on Micro Cutting

2016 ◽  
Vol 679 ◽  
pp. 103-106 ◽  
Author(s):  
Qi Ding Li ◽  
Ke Tian Li ◽  
Hai Min Li
Keyword(s):  
Finite Element ◽  
Finite Element Model ◽  
Cutting Force ◽  
Formation Mechanism ◽  
Element Model ◽  
Cutting Mechanism ◽  
Cutting Depth ◽  
Micro Cutting ◽  
Model Based ◽  
Simulation Results

A finite element model based on Abaqus/Explicit is built. Micro cutting mechanism of Al7075 with different cutting depth is simulated and analyzed. The simulation results show that if the cutting depth is more than 10μm, the chip is a kind of continuous curl. If the cutting depth is less than 10μm, the chip is a kind of feathery squeeze debris. When the cutting depth is very small (3μm), the shape of chips is just like discontinuous wrinkle. By contrasting the simulation results of cutting force with its theoretical values, they have the same result. The model of the chip prediction could achieve ideal simulation results.

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.

Finite Element Model of Human Cochlea Considering of the Helicotrema Size

2013 ◽  
Vol 456 ◽  
pp. 576-581 ◽  
Author(s):  
Li Fu Xu ◽  
Na Ta ◽  
Zhu Shi Rao ◽  
Jia Bin Tian
Keyword(s):  
Finite Element ◽  
Finite Element Model ◽  
Basilar Membrane ◽  
Round Window ◽  
Element Model ◽  
Oval Window ◽  
Fe Model ◽  
Cochlear Duct ◽  
Human Cochlea ◽  
Set Up

A 2-D finite element model of human cochlea is established in this paper. This model includes the structure of oval window, round window, basilar membrane and cochlear duct which is filled with fluid. The basilar membrane responses are calculated with sound input on the oval window membrane. In order to study the effects of helicotrema on basilar membrane response, three different helicotrema dimensions are set up in the FE model. A two-way fluid-structure interaction numerical method is used to compute the responses in the cochlea. The influence of the helicotrema is acquired and the frequency selectivity of the basilar membrane motion along the cochlear duct is predicted. These results agree with the experiments and indicate much better results are obtained with appropriate helicotrema size.

Automotive Glass Exciter Technology for Acoustic Application

2014 ◽  
Author(s):  
Babak Ebrahimi ◽  
Amir Khajepour ◽  
Todd Deaville
Keyword(s):  
Finite Element ◽  
Finite Element Model ◽  
Experimental Studies ◽  
Element Model ◽  
Fe Model ◽  
Component Level ◽  
Modeling And Analysis ◽  
Electric Actuator ◽  
Conventional Systems ◽  
Fine Tune

This paper discusses the modeling and analysis of a novel audio subwoofer system for automotive applications using the automobile windshield glass. The use of a piezo-electric actuator coupled with a mechanical amplifier linked to a large glass panel provides a highly efficient method of producing sound. The proposed subwoofer system has the advantage over existing conventional systems of not only reducing the weight of the automobile, but also a significant power savings resulting in an increase of expected fuel economy. Among various design challenges, the glass-sealing design is of huge importance, as it affects the system dynamic response and so the output sound characteristics. The main goal in this manuscript is to evaluate different glass-sealing design configurations by providing a comprehensive Finite Element model of the system. To do so, a comprehensive, yet simplified FE model is developed, and experimental studies are performed in the component level to fine-tune and verify the model. Harmonic response of the system for each sealing configuration design is obtained in the frequency range of 0–200 Hz, and the results are compared and discussed. The finite element model is also beneficial in preliminary design of other components as well as the exciter placement, and predicting the performance of the overall system.

Cutting Characteristics of Sugarcane in Terms of Physical and Chemical Properties

2020 ◽  
Vol 63 (4) ◽  
pp. 1007-1017
Author(s):  
Luxin Xie ◽  
Jun Wang ◽  
Shaoming Cheng ◽  
Dongdong Du
Keyword(s):  
Finite Element ◽  
Chemical Composition ◽  
Correlation Analysis ◽  
Finite Element Model ◽  
Physical Properties ◽  
Cutting Force ◽  
Single Point ◽  
Cutting Speed ◽  
Element Model ◽  
Cutting Process

HighlightsThe cutting mechanism of sugarcane stalks using single-point clamping was analyzed.Physical properties, chemical composition, and maximum cutting force of sugarcane were explored.Strong and complicated correlations between physical properties and chemical composition were established.Stress distributions in sugarcane stalks and the cutting blade were predicted using a finite element model.Abstract. Research on the cutting characteristics of sugarcane stalks is of great significance to improve harvest mechanization. In this study, perpendicular cutting of sugarcane stalks at six different nodes and internodes along the stalk was tested using a single-point clamping method at three cutting speeds (30, 40, and 50 mm min-1). The physical properties and chemical composition were also measured. At the 50 mm min-1 cutting speed, the maximum cutting forces at nodes and internodes upward along the stalk decreased gradually from 810 to 530 N and from 600 to 440 N, respectively. The maximum cutting force was positively correlated with the cutting speed at the same position. Differences in the microstructures of nodes, internodes, and epidermis were revealed by SEM micrographs. The physical properties and chemical composition of the stalks showed significant correlations. Correlation analysis was used to clarify the complicated interrelationships among these independent variables and revealed the interacting mechanism between physical properties and chemical composition. A finite element model was established to simulate the sugarcane cutting process. Results showed that the simulated cutting resistance of the blade was close to that in the experiments. The maximum Von Mises stress of the sugarcane stalk and blade in the cutting process were about 23.34 and 254.17 MPa, respectively. The results of this study provide guidance for designing and optimizing base-cutters of sugarcane harvesters and similar cutting equipment. Keywords: Chemical composition, Correlation analysis, Cutting characteristics, Microstructure, Physical properties, Simulation.

Design and Fatigue Life Analysis of a Motorcycle Frame

2014 ◽  
Author(s):  
Massimiliano Gobbi ◽  
Giorgio Previati ◽  
Giampiero Mastinu
Keyword(s):  
Finite Element ◽  
Fatigue Life ◽  
Finite Element Model ◽  
Experimental Tests ◽  
Element Model ◽  
Fe Model ◽  
Static Test ◽  
Weld Toe ◽  
Fatigue Life Analysis ◽  
Motorcycle Frame

An off-road motorcycle frame has been analyzed and modified to optimize its fatigue life. The fatigue life of the frame is very important to define the service life of the motorcycle. The strain levels on key parts of the frame were collected during experimental tests. It has been possible to locate the areas where the maximum stress level is reached. A finite element (FE) model of the frame has been developed and used for estimating its fatigue life. Static test bench results have been used to validate the FE model. The accuracy of the finite element model is good, the errors are always below 5% with respect to measured data. The mission profile of the motorcycle is dominated by off-road use, with stress levels close to yield point, so a strain-life approach has been applied for estimating the fatigue life of the frame. Particular attention has been paid to the analysis of the welded connections. A shell and a 3D FE model have been combined to simulate the stress histories at the welds. Two reference maneuvers have been considered as loading conditions. The computed stresses have been used to assess the life of the frame according to the notch stress approach (Radaj & Seeger). The method correlates the stress range in a idealized notch, characterized by a fictitious radius in the weld toe or root, to the fatigue life by using a single S-N curve. New technical frame layouts have been proposed and verified by means of the developed finite element model. The considered approach allows to speed up the design process and to reduce the testing phase.

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