The Investigation of Tool Wear in Metal Machining Using Finite Element Method

2009 ◽  
Vol 407-408 ◽  
pp. 395-399
Author(s):  
Hong Yan Ruan ◽  
Hua Yan ◽  
Shu Bin Lu ◽  
Hui Xia Liu ◽  
Xiao Wang
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Tool Wear ◽  
Cutting Speed ◽  
Wear Depth ◽  
Metal Machining ◽  
Tool Wear Mechanism ◽  
Cutting Model ◽  
Cutting Speeds ◽  
Element Method

The existing studies based on 2-dimension cutting model are partial investigations on tool wear. In order to get close to the true cutting conditions, the Lagrangian thermo-viscoplastic cutting simulations were conducted and the tool wears were predicted under different cutting speeds using 3-dimension finite element models. The simulation results indicate that when the cutting speed increases the cutting forces will reduce accordingly while the wear depth will be deeper. As a result, different factors should be considered at the same time when the speed range is selected. This study has shown that the finite element method is a valuable approach to understand the tool wear mechanism in machining and the influences of different cutting speeds.

Evaluation of Thermal Effects in Turning Processes: Numerical and Experimental Approach

2019 ◽  
Author(s):  
Aruna Prabha Kolluri ◽  
Srinivasa Prasad Balla ◽  
Satya Prasad Paruchuru
Keyword(s):  
Finite Element ◽  
Temperature Distribution ◽  
Tool Wear ◽  
Wear Mechanism ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Tool Material ◽  
Maximum Error ◽  
Tool Wear Mechanism ◽  
Coated Carbide

Abstract The 3D Finite element method (FEM) is an efficient tool to predict the variables in the cutting process, which is otherwise challenging to obtain with the experimental methods alone. The present study combines both experimental findings and finite element simulation outcomes to investigate the effect of tool material on output process variables, such as vibrations, cutting temperature distribution and tool wear mechanism. Machining of popular aerospace materials like Ti-6Al-4V and Al7075 turned with coated and uncoated tools are part of the investigation. The authors choose the orthogonal test, measured vibrations and cutting temperatures and used FE simulations to carry out the subsequent validations. This study includes the influence of the predicted heat flux and temperature distribution on the tool wear mechanism. The main aim of this study is to investigate the performance quality of uncoated and coated carbide tools along with its thermal aspects. Comparison of experiment and simulation outcomes shows good agreement with a maximum error of 9.02%. It has been noted that the increase of cutting temperature is proportional to its cutting speed. As the cutting speed increases, it is observed that vibration parameter and flank wear value also increases. Overall, coated carbide turning insert tool is the best method for metal turning with higher rotational speeds of the spindle.

Micro Machining Simulation Analysis by Finite Element Method

2013 ◽  
Vol 712-715 ◽  
pp. 575-578
Author(s):  
Zhan Min Yin ◽  
Yu Juan Dai
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Simulation Analysis ◽  
Cutting Speed ◽  
Failure Criteria ◽  
Rake Angle ◽  
Depth Of Cut ◽  
Micro Machining ◽  
Machining Processes ◽  
Element Method

Micro machining becomes more and more important with the tendency of miniaturization of components used in various fields from military to civilian applications. The finite element method software Abaqus is used to model the nonlinear thermal force coupled elastic-plastic micro machining processes. Relatively systematic simulation analysis has been introduced based on the model combining the Johnson-Cook failure criteria, element deletion strategy etc. It reveals that the size effect is dominant while the depth of cut reaches the cutting edge radius. The rake angle plays more important roles on the micro machining than that of the cutting speed.

Finite Element Simulation of Cutting Forces in Orthogonal Machining of Titanium Alloy Ti-6Al-4V

2014 ◽  
Vol 474 ◽  
pp. 192-199 ◽  
Author(s):  
Ladislav Kandráč ◽  
Ildikó Maňková ◽  
Marek Vrabel' ◽  
Jozef Beňo
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Cutting Forces ◽  
Orthogonal Cutting ◽  
Experimental Studies ◽  
Cutting Speed ◽  
Rake Angle ◽  
Simulation Software ◽  
Tool Geometry ◽  
Element Method

In this paper, a Lagrangian finite element-based machining model is applied in the simulation of cutting forces in two-dimensional orthogonal cutting of titanium Ti-6Al-4V alloy. The simulations were conducted using 2D Finite Element Method (FEM) machining simulation software. In addition, the cutting experiments were carried out under the different cutting speed, feed and tool geometry (rake angle, clearance angle and cutting edge radius). The effect of cutting speed, feed and tool geometry on cutting force were investigated. The results obtained from the finite element method (FEM) and experimental studies were compared.

Cutting Forces and Tool Wear in Dry Milling of Ti6Al4V

2012 ◽  
Vol 565 ◽  
pp. 454-459 ◽  
Author(s):  
Yun Chen ◽  
Huai Zhong Li ◽  
Jun Wang
Keyword(s):  
Tool Wear ◽  
Cutting Forces ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Dry Milling ◽  
Workpiece Material ◽  
Tool Wear Mechanism ◽  
Coated Carbide ◽  
Carbide Inserts ◽  
Cutting Speeds

Titanium alloys are difficult-to-cut materials. This paper presents an experimental study of the effects of different cutting conditions and tool wear on cutting forces in dry milling Ti6Al4V with coated carbide inserts. The experimental results show that the peak forces increase with the increase in the feed rate and depth of cut. With the cutting speed increment in the range from 50 m/min to 150 m/min the peak forces decrease, while at further higher cutting speeds investigated peak forces increase. The decrease of the peak forces is due to thermal softening of the workpiece material and the increase is because of the strain hardening rate of Ti6Al4V. The tool wear experiment reveals that the major tool wear mechanism is the flank wear. The variations of the peak forces are caused by both the tool wear propagation and the thermal effects.

Further Developments in Applying the Finite Element Method to the Calculation of Temperature Distributions in Machining and Comparisons With Experiment

1983 ◽  
Vol 105 (3) ◽  
pp. 149-154 ◽  
Author(s):  
M. G. Stevenson ◽  
P. K. Wright ◽  
J. G. Chow
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Temperature Fields ◽  
The Finite Element Method ◽  
Finite Element Program ◽  
Temperature Distributions ◽  
Wide Range ◽  
Metal Machining ◽  
Element Program ◽  
Element Method

The finite element program developed in previous work [1] for calculating the temperature distributions in the chip and tool in metal machining has been extended in its range of application. Specifically, the program no longer needs a flow field as input and it can accommodate a wide range of shear angle and contact lengths. An important feature of this paper is that temperature fields from the finite element method have been compared with temperatures obtained with a previously described metallographic method [7]. This is the first time these two techniques have been used for the same machining conditions and the comparisons are very good.

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