Finite Element Modeling for Prediction of Stress – Strain at Several Feed Rates and Cutting Speeds for Titanium (Ti-6Al-4V) Alloy

2012 ◽  
Vol 587 ◽  
pp. 11-15
Author(s):  
Moaz H. Ali ◽  
Basim A. Khidhir ◽  
Bashir Mohamed
Keyword(s):  
Finite Element ◽  
Orthogonal Cutting ◽  
Cutting Speed ◽  
Equivalent Strain ◽  
Machining Process ◽  
Depth Of Cut ◽  
General Corrosion ◽  
Explicit Finite Element ◽  
Finite Element Software ◽  
Cutting Speeds

Titanium (Ti-6Al-4V) alloy is a desirable material for the aircraft industry because of their excellent properties behaves of high specific strength, fracture resistant characteristics, lightweight and general corrosion resistance. This paper presents a study on a two-dimensional orthogonal cutting process by using a face-milling operation through ABAQUS/EXPLICIT finite-element software. Several tests were performed at various feed rates and cutting speeds while the depth of cut remains constant. The results led to the conclusion that the stress components at integration points (Von - Mises) and the equivalent strain (PEEQ) were increased with increasing the feed rate and cutting speed during the machining process.

Finite Element Analysis of the Effect of Cutting Speed on the Orthogonal Turning of A359/SiCp MMC

2016 ◽  
Vol 852 ◽  
pp. 304-310
Author(s):  
M.M. Thamizharasan ◽  
Y.J. Nithiya Sandhiya ◽  
K.S. Vijay Sekar ◽  
V.V. Bhanu Prasad
Keyword(s):  
Finite Element ◽  
Matrix Material ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Fe Model ◽  
Element Analysis ◽  
Damage And Fracture ◽  
Orthogonal Turning ◽  
The Matrix ◽  
Cutting Speeds

The application of Metal Matrix Composite (MMC) has been increasing due to its superior strength and wear characteristics but the major challenge is its poor machinability due to the presence of reinforcement in the matrix which is a hindrance during machining. The material behaviour during machining varies with respect to input variables. In this paper the effect of cutting speed during the orthogonal turning of A359/SiCp MMC with TiAlN tool insert is analysed by developing a 2D Finite Element (FE) model in Abaqus FEA code. The FE model is based on plane strain formulation and the element type used is coupled temperature displacement. The matrix material is modeled using Johnson–Cook (J-C) thermal elastic–plastic constitutive equation and chip separation is simulated using Johnson–Cook’s model for progressive damage and fracture with parting line. Particle material is considered to be perfectly elastic until brittle fracture. The tool is considered to be rigid. The FE model analyses the tool interaction with the MMC and its subsequent effects on cutting forces for different cutting speeds and feed rates. The chip formation and stress distribution are also studied. The FE results are validated with the experimental results at cutting speeds ranging from 72 – 188 m/min and feed rates ranging from 0.111 – 0.446 mm/rev at constant depth of cut of 0.5mm.

Cutting forces analysis of micro-milling process on Inconel 718 – a finite element approach

2020 ◽  
Vol 11 (02) ◽  
pp. 2050011
Author(s):  
Padmaja Tripathy ◽  
Kalipada Maity
Keyword(s):  
Finite Element ◽  
Cutting Forces ◽  
Inconel 718 ◽  
Cutting Speed ◽  
Fem Analysis ◽  
Milling Process ◽  
Machining Process ◽  
Micro Milling ◽  
Depth Of Cut ◽  
Machining Parameters

This paper presents a modeling and simulation of micro-milling process with finite element modeling (FEM) analysis to predict cutting forces. The micro-milling of Inconel 718 is conducted using high-speed steel (HSS) micro-end mill cutter of 1mm diameter. The machining parameters considered for simulation are feed rate, cutting speed and depth of cut which are varied at three levels. The FEM analysis of machining process is divided into three parts, i.e., pre-processer, simulation and post-processor. In pre-processor, the input data are provided for simulation. The machining process is further simulated with the pre-processor data. For data extraction and viewing the simulated results, post-processor is used. A set of experiments are conducted for validation of simulated process. The simulated and experimental results are compared and the results are found to be having a good agreement.

NC Turning Process Parameters Optimization Based on Simulation Software

2012 ◽  
Vol 271-272 ◽  
pp. 452-456
Author(s):  
Shu Feng Sun ◽  
Ping Ping Wang ◽  
Xin Wu ◽  
Sen Lin
Keyword(s):  
Finite Element ◽  
Cutting Force ◽  
Process Parameters ◽  
Feed Rate ◽  
Cutting Speed ◽  
Simulation Software ◽  
Parameters Optimization ◽  
Machining Process ◽  
Optimum Process ◽  
Finite Element Software

Machining process parameters are main factors influencing machining quality and efficiency. Finite element models of tool and part are set up using finite element software Deform-3D. Variety laws of cutting force and temperature under different process parameters are simulated. The results are analyzed. Cutting force grows obviously with the growth of cutting speed (vc). However, cutting force fluctuates and decreases with the growth of cutting depth (ap) indicating the phenomenon of work hardening. Cutting force fluctuates and grows with the growth of feed rate ( f ). But the influence of feed rate ( f ) to cutting force is smaller than that of cutting speed (vc). The growths of the above mentioned three process parameters all cause the rise of temperature. Machining simulation research provides the optimum process parameters for CNC programming.

Study on Residual Stress in High-Speed Cutting NAK80 Mold-Steel

2012 ◽  
Vol 217-219 ◽  
pp. 458-462
Author(s):  
Jian Xin Pan ◽  
Zhi Xiong Zhou
Keyword(s):  
Residual Stress ◽  
Finite Element ◽  
High Speed ◽  
Orthogonal Cutting ◽  
Tool Geometry ◽  
Stress Distributions ◽  
High Speed Cutting ◽  
Finite Element Software ◽  
Cutting Model ◽  
Cutting Speeds

An orthogonal cutting model was presented，and the cutting process was simulated by a finite element software based on the thermal-elastic-plastic FEM theory and updated Lagrange method.We obtained the distributions of residual stresses in machined layer of NAK80 mold-steel.The effects of cutting speeds，cutting depths and tool geometry on residual stress distributions were investigated. Comparing to experimental results，the conclusions are more accurate.

Finite Element Simulation Research on a Large Cutting Depth and Quasi-High Speeds 3-D Milling of Titanium Alloys

2014 ◽  
Vol 800-801 ◽  
pp. 269-274
Author(s):  
Shu Tao Huang ◽  
Wan Yong Chen ◽  
Li Zhou
Keyword(s):  
Finite Element ◽  
Titanium Alloys ◽  
Cutting Force ◽  
Feed Rate ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Cutting Depth ◽  
Finite Element Software ◽  
High Speeds

In this paper, based on finite element software DEFORM, the model of a large cutting depth and quasi-high speeds milling of titanium alloys is built to study the cutting temperature and cutting force variation along with the change of cutting parameters. The simulation results show that: the location of the maximum cutting temperature appears in the cutting edges of the tool nose circular profile. Meanwhile, due to workpiece material rebound in the cutting process, the interface between workpiece and tool flank face occurs serious extrusion, which results in relatively high cutting temperature on the workpiece machined surface. In addition, cutting speed and feed rate per tooth play a key role in influencing the cutting temperature. However, the influence of cutting depth on the cutting temperature is less clear. With the increase in the feed rate and depth of cut, cutting force increased significantly. In particular, within the scope of the cutting speeds under the given conditions, the cutting force has a tendency to decrease with the cutting speed increasing over 120m/min.

scholarly journals Studi Eksperimen Pengaruh Variasi Kecepatan Potong dan Kedalaman Pemotongan Terhadap Kekasaran Permukaan Benda Kerja Hasil Pembubutan Material Baja ST 41 Menggunakan Pahat HSS

2021 ◽  
Vol 3 (1) ◽  
pp. 65-72
Author(s):  
Ardyan - ◽  
Erwansyah - ◽  
Yang Fitri Arriyani
Keyword(s):  
Surface Roughness ◽  
Experimental Method ◽  
Experimental Research ◽  
Cutting Speed ◽  
Machining Process ◽  
Depth Of Cut ◽  
Turning Process ◽  
Cutting Depth ◽  
Feeding Speed ◽  
Cutting Speeds

The benchmark for the results of the machining process can be seen from the results of the products, one of which is the level of surface smoothness. The purpose of this experimental research is to find out how much cutting speed (Vc) and depth of cutting produce a workpiece with the smoothest level of surface roughness for the turning process carried out by students at the Bangka Belitung State Manufacturing Polytechnic Workshop. This research is using experimental method. The cutting speeds (Vc) used were 23 m/min, 24 m/min, 25 m/min, the cutting depths used were 0.5 mm, 0.8 mm, and 1.0 mm and the feeding speed was set at 0.040 mm/rev. The results showed that the best turning results using a cutting speed (Vc) of 23 m/min was using a cutting depth of 0.5 mm with a roughness value (Ra) of 1.372 m, using a cutting speed (Vc) of 24 m/min using a depth of cut. 0.5 mm with a roughness value (Ra) of 1.189 m and using a cutting speed (Vc) of 25 m/min using a depth of 0.5 mm with a surface roughness value (Ra) of 3.14 m. The lowest value for the level of surface roughness of the turning process was obtained using a cutting speed (Vc) of 24 m/min with a depth of 0.5 mm with a surface roughness value (Ra) of 1.189 m.

scholarly journals Influence of Cutting Speed on Residual Stresses by Machining of AISI 316L

2020 ◽  
Vol 38 (3A) ◽  
pp. 394-401
Author(s):  
Safa M. Lafta ◽  
Maan A. Tawfiq
Keyword(s):  
Residual Stresses ◽  
Orthogonal Cutting ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Aisi 316L ◽  
X Ray Diffraction ◽  
Beverage Industry ◽  
Food And Beverage Industry ◽  
Food And Beverage ◽  
Cutting Speeds

RS have an important role in the performance of components and machined structures. The objective of this paper is to study the influence of cutting speed on RS in workpieces that are formed in orthogonal cutting. AISI 316L stainless steel since it has been used in many important industries such as chemical, petrochemical industries, power generation, electrical engineering, and food and beverage industry. Four cutting speeds are selected: (44, 56, 71 and 88) m/min. The alloy was machined by turning at constant depth of cut and various feed rate from (0.065 to 0.228) mm/rev. Residual stresses are examined by X-ray diffraction. The best results of RS obtained are (-3735.28, -1784.95, -330.142, -218.747, -890.758, -2999.632, -2990.401) MPa. Increasing the cutting speed from (44-56) m/min. reduces the compressive residual stress by (21.4 %), while from (71-88) m/min the RS is reduced by (19.3 %). Finally, the RS at cutting speeds are changed from compression to tension.

Dry Machining of T6061 Aluminium Alloy Using Titanium Nitride (TiN) and Titanium Carbonitride (TiCN) Coated Tools

2013 ◽  
Vol 284-287 ◽  
pp. 291-295 ◽  
Author(s):  
Tasnim Firdaus Ariff ◽  
Muhamad Fahmie Paimin ◽  
Abdirahman Hassan
Keyword(s):  
Aluminium Alloy ◽  
Cutting Speed ◽  
Machining Process ◽  
Titanium Carbonitride ◽  
Depth Of Cut ◽  
Dry Machining ◽  
Coated Tools ◽  
Coated Tool ◽  
Optimum Cutting ◽  
Cutting Speeds

Dry machining is a clean machining process and it will be considered as a necessity for manufacturing industries in future. Dry machining is environmental friendly and safe to be performed. Regardless of decreasing tool life due to lack of lubricants, choosing dry machining over wet machining may be a wiser choice since the cost of purchasing and disposing the cutting fluids can contribute to a higher cost. Tool wear intensities of TiN and TiCN coated tools using both dry and traditional wet machining was studied with the aim in finding the optimum cutting speed from three different cutting speeds (318, 394 and 490 m/min) with a feed rate of 0.6 mm/rev and depth of cut of 0.4 mm. Tool tip temperature was also analyzed to see the effect of temperature rise at the tool-chip interface. TiCN coated tool performed better than TiN coated tool since the wear rate for TiCN coated tool is smaller by 40-48 % when compared to TiN coated tool for dry machining for all three cutting speeds. The optimum cutting speed for dry machining of T6061 Aluminium alloy using TiN and TiCN coated tools is 394 m/min. Tool tip temperature for dry machining is also slightly higher than wet machining by 19 and 32 % for TiN and TiCN coated tools respectively at the optimum cutting speed. Dry machining of T6061 Aluminium alloy can be a more suitable eco-friendly machining process particularly at high cutting speed for interrupted cutting operations.

Deformation Replication

1970 ◽  
Vol 28 ◽  
pp. 280-281
Author(s):  
J. Temple Black
Keyword(s):  
Cutting Speed ◽  
Machining Process ◽  
Depth Of Cut ◽  
Rake Face ◽  
Orthogonal Machining ◽  
Aluminum Chips ◽  
Before And After ◽  
Materials Used ◽  
Glass Knife ◽  
Very High

Tool materials used in ultramicrotomy are glass, developed by Latta and Hartmann (1) and diamond, introduced by Fernandez-Moran (2). While diamonds produce more good sections per knife edge than glass, they are expensive; require careful mounting and handling; and are time consuming to clean before and after usage, purchase from vendors (3-6 months waiting time), and regrind. Glass offers an easily accessible, inexpensive material ($0.04 per knife) with very high compressive strength (3) that can be employed in microtomy of metals (4) as well as biological materials. When the orthogonal machining process is being studied, glass offers additional advantages. Sections of metal or plastic can be dried down on the rake face, coated with Au-Pd, and examined directly in the SEM with no additional handling (5). Figure 1 shows aluminum chips microtomed with a 75° glass knife at a cutting speed of 1 mm/sec with a depth of cut of 1000 Å lying on the rake face of the knife.

Experimental and Numerical Investigation into Residual Stress During Turning Operation for Stainless Steel AISI 316

2020 ◽  
Vol 38 (12A) ◽  
pp. 1862-1870
Author(s):  
Safa M. Lafta ◽  
Maan A. Tawfiq
Keyword(s):  
Stainless Steel ◽  
Residual Stresses ◽  
Orthogonal Cutting ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Percentage Error ◽  
Depth Of Cut ◽  
Main Role ◽  
Turning Operation ◽  
Aisi 316

RS (residual stresses) represent the main role in the performance of structures and machined parts. The main objective of this paper is to investigate the effect of feed rate with constant cutting speed and depth of cut on residual stresses in orthogonal cutting, using Tungsten carbide cutting tools when machining AISI 316 in turning operation. AISI 316 stainless steel was selected in experiments since it is used in many important industries such as chemical, petrochemical industries, power generation, electrical engineering, food and beverage industry. Four feed rates were selected (0.228, 0.16, 0.08 and 0.065) mm/rev when cutting speed is constant 71 mm/min and depth of cutting 2 mm. The experimental results of residual stresses were (-15.75, 12.84, 64.9, 37.74) MPa and the numerical results of residual stresses were (-15, 12, 59, and 37) MPa. The best value of residual stresses is (-15.75 and -15) MPa when it is in a compressive way. The results showed that the percentage error between numerical by using (ABAQUS/ CAE ver. 2017) and experimental work measured by X-ray diffraction is range (2-15) %.

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