Numerical Simulation and Prediction of Cutting Force in Turning of Titanium Alloy

2012 ◽  
Vol 580 ◽  
pp. 63-66 ◽  
Author(s):  
Bin Li ◽  
Hong Wang
Keyword(s):  
Numerical Simulation ◽  
Cutting Force ◽  
Material Flow ◽  
Flow Behavior ◽  
Metal Flow ◽  
Cutting Speed ◽  
Machining Process ◽  
Engineering Technology ◽  
Metal Machining ◽  
Tc4 Alloy

Though titanium alloys are being increasingly sought in a wide variety of engineering and biomedical applications, their manufacturability, especially machining and grinding imposes lot of constraints. With the development of engineering technology, FEM can be used to simulate metal machining process and gain better understanding of material flow within dies, so as to optimize tooling to eliminate tears, laps and other forging defects. In this paper, numerical simulation was conducted by using FEM software on the whole cutting process for TC4 alloy mounting parts in an effort to investigate the metal flow behavior. The calculated cutting force increases approximately logarithmically with the cutting speed, as should be expected from the logarithmic rate dependence.

An Analytical Finite Element Technique for Predicting Temperature Distribution in Turning Titanium Alloy

2012 ◽  
Vol 184-185 ◽  
pp. 886-889
Author(s):  
Bin Li ◽  
Hong Wang
Keyword(s):  
Material Flow ◽  
Flow Behavior ◽  
Metal Flow ◽  
Cutting Temperature ◽  
Machining Process ◽  
Engineering Technology ◽  
Metal Machining ◽  
Tc4 Alloy ◽  
Simulation Results ◽  
Element Technique

With the development of engineering technology, FEM can be used to simulate metal machining process and gain better understanding of material flow within dies, so as to optimize tooling to eliminate tears, laps and other forging defects. In this paper, numerical simulation was conducted by using FEM software on the whole cutting process for TC4 alloy mounting parts in an effort to investigate the metal flow behavior. The thermal simulation results obtained were compared with the cutting temperature and discussed in terms of literature data.

Finite Element Technique for Predicting Stress Distribution in Milling TC4 Titanium Alloy

2014 ◽  
Vol 623 ◽  
pp. 121-124
Author(s):  
Bin Li ◽  
Shu Ling Zhao
Keyword(s):  
Finite Element ◽  
Titanium Alloy ◽  
Material Flow ◽  
Cutting Speed ◽  
Milling Process ◽  
Machining Process ◽  
Engineering Technology ◽  
Tc4 Titanium Alloy ◽  
Metal Machining ◽  
Element Technique

Cutting forces modeling is the basis to understand, simulate milling process and further to control milling process parameters for obtaining higher precision workpieces. With the development of engineering technology, FEM can be used to simulate metal machining process and gain better understanding of material flow within dies, so as to optimize tooling to eliminate tears, laps and other forging defects. In this paper, the calculated cutting force increases approximately logarithmically with the cutting speed, as should be expected from the logarithmic rate dependence.

Numerical Simulation and Thermal Analysis in Milling of Titanium Alloy

2012 ◽  
Vol 503-504 ◽  
pp. 556-559
Author(s):  
Bin Li
Keyword(s):  
Numerical Simulation ◽  
Titanium Alloy ◽  
Flow Behavior ◽  
Metal Flow ◽  
Cutting Temperature ◽  
Cutting Process ◽  
Finishing Process ◽  
Tc4 Alloy ◽  
Simulation Results

Milling of titanium alloy is usually a finishing process, therefore stable cutting process must be guaranteed at first. Temperature distributions were studied in this paper with the help of finite element method (FEM) for its significant influence on the quality of machined part. In this paper, numerical simulation was conducted by using FEM software on the whole cutting process for TC4 alloy mounting parts in an effort to investigate the metal flow behavior. The thermal simulation results obtained were compared with the cutting temperature.

Modeling of the Temperature Distribution in Machining TC4 Titanium Alloy

2012 ◽  
Vol 182-183 ◽  
pp. 945-949
Author(s):  
Bin Li ◽  
Hong Wang
Keyword(s):  
Numerical Simulation ◽  
Titanium Alloy ◽  
Flow Behavior ◽  
Metal Flow ◽  
Cutting Process ◽  
Trial And Error ◽  
Tc4 Titanium Alloy ◽  
Tc4 Alloy ◽  
Beta Structure ◽  
Alpha Beta

As one of the most commonly used titanium alloys, TC4 (Ti6Al4V) has an alpha–beta structure and is widely used for aircraft components. In this study, numerical simulation was conducted by using FEM software on the whole cutting process for TC4 alloy mounting parts in an effort to investigate the metal flow behavior. This study not only helps to understand but also to improve and optimize cutting process, which are based on experience combined with a trial-and-error approach.

scholarly journals Numerical Simulation of Rock Plate Cutting with Three Sides Fixed and One Side Free

2018 ◽  
Vol 2018 ◽  
pp. 1-21 ◽  
Author(s):  
Zhenguo Lu ◽  
Lirong Wan ◽  
Qingliang Zeng ◽  
Xin Zhang ◽  
Kuidong Gao
Keyword(s):  
Numerical Simulation ◽  
Cutting Force ◽  
Cutting Speed ◽  
Rock Cutting ◽  
Numerical Results ◽  
Peak Force ◽  
Cutting Performance ◽  
Conical Pick ◽  
Cutting Method ◽  
Cutting Angle

In order to overcome conical pick wear in the traditional rock cutting method, a new cutting method was proposed on account of increasing free surface of the rock. The mechanical model of rock plate bending under concentrated force was established, and the first fracture position was given. The comparison between experimental and numerical results indicated that the numerical method is effective. A computer code LS-DYNA (3D) was employed to study the cutting performance of a conical pick. To study the rock size influenced on the cutting performance, the numerical simulations with different thickness, width, and height of a rock plate was carried out. The numerical simulation with the different cutting parameters of cutting speed, cutting angle, and cutting position influenced on cutting performance was also carried out. The numerical results indicated that the peak force increased with the increasing thickness of rock plate. With the increasing width and height of the rock plate, the peak force decreased and then became stable. Besides, the peak force decreased with the increasing of cutting position lxp/lx. Moreover, the peak force increased and then decreased with the increasing of cutting angle. The cutting speed has nonsignificant influence on the peak force. The strong exponential relationship was obtained between the peak force and cutting position, thickness, height, and width of the rock plate at a confidence level of 0.95. A binomial relationship was observed between the peak force and cutting angel. The cutting force comparison between traditional rock cutting and rock plate cutting indicated that the new cutting method can effectively reduce peak cutting force.

scholarly journals Experimental study on cutting parameters and machining paths of SiCp/Al composite thin-walled workpieces

2020 ◽  
Vol 29 ◽  
pp. 2633366X2094252
Author(s):  
Yunan Liu ◽  
Shutao Huang ◽  
Keru Jiao ◽  
Lifu Xu
Keyword(s):  
Cutting Force ◽  
Volume Fraction ◽  
Cutting Speed ◽  
Aluminum Matrix ◽  
Machining Process ◽  
Cutting Depth ◽  
Processing Efficiency ◽  
Al Composite ◽  
Edge Defects ◽  
Thin Walled

Thin-walled workpieces of silicon carbide particle-reinforced aluminum matrix (SiCp/Al) composites with outstanding properties have been widely applied in many fields, such as automobile, weapons, and aerospace. However, the thin-walled workpieces exhibit poor rigidity, large yield ratio, and easily deform under the cutting force and cutting heat during the machining process. Herein, in order to improve the processing efficiency and precision of higher volume fraction SiCp/Al composite thin-walled workpieces, the influence of different high-speed milling parameters and machining paths on the edge defects is analyzed. The results reveal that the cutting force initially increased and then decreased with the cutting speed. Besides, the cutting force steadily increased with radial cutting depth and feed per tooth, but the influence of feed per tooth is less than radial cutting depth. After up-milling cut-in and cut-out processing and down-milling cut-out processing, the cut-in end of the workpiece exhibited higher breakage and obvious edge defects. However, the workpiece edges remained intact after down-milling cut-in processing. In conclusion, a higher cutting speed, a smaller radial cutting depth, and moderate feed per tooth are required to decrease the cutting force during the milling of SiCp/Al composite thin-walled workpiece. Furthermore, down-milling cut-in processing mode can reduce the edge defects and improve the processing efficiency and precision of the workpiece.

Numerical Analysis of Multi-Field Coupled Phenomena in Friction Stir Welding and Applications

2014 ◽  
Vol 783-786 ◽  
pp. 1794-1807
Author(s):  
Qing Yu Shi ◽  
Gao Qiang Chen ◽  
Xi Bo Wang ◽  
Xu Kang
Keyword(s):  
Numerical Simulation ◽  
Friction Stir Welding ◽  
Heat Generation ◽  
Material Flow ◽  
Metal Flow ◽  
Friction Stir ◽  
Rate Dependent ◽  
Potential Applications ◽  
Complex Phenomena ◽  
Fsw Parameters

Friction stir welding (FSW) is an advanced solid state joining technology, which was invented by TWI in 1991. During the process, large amount of heat is generated due to the friction between the tool and the material. As a result, the metal around the tool is softened as the temperature rises, and significant plastic flow occurs. So FSW is a complex process with multi-field coupled phenomena. Material flow plays a central role in FSW. But it is still difficult to reveal the material flow regime and joining mechanism during FSW process. Numerical simulation is a powerful tool for investigating the metal-flow-related complex phenomena during FSW. Meanwhile, numerical simulation could also help to optimize FSW tool design and FSW parameters. In this paper, we review the recent development in simulation of material flow during FSW. Then, the important issues in modeling multi field coupled phenomena during FSW are summarized, which include the heat generation mechanism, the temperature and strain rate dependent material’s behavior, and the interaction between tool and material. Finally, a comprehensive simulation model is presented, which enables advanced study on the coupled phenomena of heat generation, temperature distribution, material flow, and defects formation. This model has shown potential applications in simulating the relation between the transport of material and the macrostructure formation or defects formation. In spite of these progresses, simulation of material flow during FSW still need quite a lot of researches to fulfill industry requirement.

scholarly journals Experimental Investigation on Dry Routing of CFRP Composite: Temperature, Forces, Tool Wear, and Fine Dust Emission

Materials ◽  
2021 ◽  
Vol 14 (19) ◽  
pp. 5697
Author(s):  
Tarek Elgnemi ◽  
Victor Songmene ◽  
Jules Kouam ◽  
Martin B.G. Jun ◽  
Agnes Marie Samuel
Keyword(s):  
Tool Wear ◽  
Cutting Force ◽  
Dust Emission ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Machining Process ◽  
Specific Cutting Energy ◽  
Fine Dust ◽  
Cutting Energy ◽  
Cutting Speeds

This article presents the influence of machining conditions on typical process performance indicators, namely cutting force, specific cutting energy, cutting temperature, tool wear, and fine dust emission during dry milling of CFRPs. The main goal is to determine the machining process window for obtaining quality parts with acceptable tool performance and limited dust emission. For achieving this, the cutting temperature was examined using analytical and empirical models, and systematic cutting experiments were conducted to assess the reliability of the theoretical predictions. A full factorial design was used for the experimental design. The experiments were conducted on a CNC milling machine with cutting speeds of 10,000, 15,000, and 20,000 rpm and feed rates of 2, 4, and 6 µm/tooth. Based on the results, it was ascertained that spindle speed significantly affects the cutting temperature and fine particle emission while cutting force, specific cutting energy, and tool wear are influenced by the feed rate. The optimal conditions for cutting force and tool wear were observed at a cutting speed of 10,000 rpm. The cutting temperature did not exceed the glass transition temperature for the cutting speeds tested and feed rates used. The fine particles emitted ranged from 0.5 to 10 µm aerodynamic diameters with a maximum concentration of 2776.6 particles for those of 0.5 µm diameters. Finally, results of the experimental optimization are presented, and the model is validated. The results obtained may be used to better understand specific phenomena associated with the milling of CFRPs and provide the means to select effective milling parameters to improve the technology and economics of the process.

scholarly journals The effect of changes in depth of cut and cutting speed of CNC toolpaths on turning process performance

2018 ◽  
Vol 38 (1) ◽  
pp. 40-44
Author(s):  
Krzysztof Jarosz ◽  
Piotr Niesłony ◽  
Piotr Löschner
Keyword(s):  
Cutting Force ◽  
Tool Life ◽  
Cutting Speed ◽  
Machining Process ◽  
Depth Of Cut ◽  
Process Performance ◽  
Turning Process ◽  
Machining Time ◽  
Toolpath Optimization ◽  
The Impact

Abstract In this article, a novel approach to computer optimization of CNC toolpaths by adjustment of cutting speed vcand depth of cut apis presented. Available software works by the principle of adjusting feed rate on the basis of calculations and numerical simulation of the machining process. The authors wish to expand upon this approach by proposing toolpath optimization by altering two other basic process parameters. Intricacies and problems related totheadjustment of apand vcwere explained in the introductory part. Simulation of different variant of the same turning process with different parameter values were conducted to evaluate the effect of changes in depth of cut and cutting speed on process performance. Obtained results were investigated on the account of cutting force and tool life. The authors have found that depth of cut substantially affects cutting force, while the effect of cutting speed on it is minimal. An increase in both depth of cut and cutting speed affects tool life negatively, although the impact of cutting speed is much more severe. An increase in depth of cut allows for a more significant reduction of machining time, while affecting tool life less negatively. On the other hand, the adjustment of cutting speed helpsto reduce machining time without increasing cutting force component values and spindle load.

scholarly journals Effects of Turning Parameters and Parametric Optimization of the Cutting Forces in Machining SiCp/Al 45 wt% Composite

Metals ◽  
2020 ◽  
Vol 10 (6) ◽  
pp. 840 ◽  
Author(s):  
Rashid Ali Laghari ◽  
Jianguang Li ◽  
Mozammel Mia
Keyword(s):  
Mathematical Model ◽  
Cutting Force ◽  
Feed Rate ◽  
Cutting Forces ◽  
Desirability Function ◽  
Interactive Effect ◽  
Cutting Speed ◽  
Experimental Results ◽  
Machining Process ◽  
Depth Of Cut

Cutting force in the machining process of SiCp/Al particle reinforced metal matrix composite is affected by several factors. Obtaining an effective mathematical model for the cutting force is challenging. In that respect, the second-order model of cutting force has been established by response surface methodology (RSM) in this study, with different cutting parameters, such as cutting speed, feed rate, and depth of cut. The optimized mathematical model has been developed to analyze the effect of actual processing conditions on the generation of cutting force for the turning process of SiCp/Al composite. The results show that the predicted parameters by the RSM are in close agreement with experimental results with minimal error percentage. Quantitative evaluation by using analysis of variance (ANOVA), main effects plot, interactive effect, residual analysis, and optimization of cutting forces using the desirability function was performed. It has been found that the higher depth of cut, followed by feed rate, increases the cutting force. Higher cutting speed shows a positive response by reducing the cutting force. The predicted and experimental results for the model of SiCp/Al components have been compared to the cutting force of SiCp/Al 45 wt%—the error has been found low showing a good agreement.

Sign in / Sign up

Export Citation Format

Share Document