Study on the Effect of Tool Inclination Angle in Machining Process Based on Three-Dimensional Thermo-Elastic-Plastic Model

2009 ◽  
Vol 407-408 ◽  
pp. 444-447
Author(s):  
Hui Yue Dong ◽  
Hui Xue ◽  
Pu Jin Huang
Keyword(s):  
Inclination Angle ◽  
High Speed ◽  
Virtual Work ◽  
Three Dimensional ◽  
Cutting Temperature ◽  
Friction Model ◽  
Machining Process ◽  
Workpiece Material ◽  
Flow Angle ◽  
Elastic Plastic

Based on large deformation theory and virtual work principle, a coupled three-dimensional (3D) thermo-elastic-plastic finite element model (FEM) was constructed to simulate the high speed cutting process of Al7050-T7451. The mechanical properties of workpiece material under conditions of high temperature and high strain rate were defined in the model. A shear friction model was involved at the interfaces of tool-chip, tool-workpiece. Based on the model, different 3D machining FEM with different inclination angles were established, and distributions of stress, strain and temperature were achieved. Further more, the effects of inclination angle on the chip curling direction, chip flow angle, cutting force and cutting temperature were studied.

Study on the Orthogonal Cutting Process of Al7050T7451 with Uncoated and Coated Tools

2008 ◽  
Vol 392-394 ◽  
pp. 990-995 ◽  
Author(s):  
Hui Yue Dong ◽  
Pu Jin Huang ◽  
Y.B. Bi
Keyword(s):  
Finite Element ◽  
High Speed ◽  
High Strain ◽  
Bulk Material ◽  
Orthogonal Cutting ◽  
Cutting Temperature ◽  
Machining Process ◽  
Workpiece Material ◽  
Coated Tool ◽  
The Impact

Tool wear during high speed machining process plays an important role in machining cost and efficiency. The purpose of this study is to examine the impact of tribological properties of coatings on cutting performance. Finite element methods (FEM) were used to model the effect of coated and uncoated cutting tools (K10) on the machinability of the aluminum alloy 7050T7451. Uncoated, Single coated, such as TiC, TiN and Al2O3 and multi-coated tool were studied. All finite element models were assumed to be plane strain. To achieve constitutive model of Al7050T7451 under conditions of machining that high strain rate, high strain and high temperature occur, high speed impact experiment and material drawing experiment were done. Comparison of FEM results shows that the highest temperatures in tools, the temperature change rates of different tools from surface to its bulk material, and the temperatures in chips are changed greatly. It also shows that the cutting temperature of coated tool is lower than uncoated tools, but cutting forces change very little. All these results show that coatings can be used to reduce adhesion between a tool and a workpiece material. The wear resistance of coated tool can be improved effectively and tool life is increased correspondingly.

Research on Dynamic Physical Simulation of HSC Comprehensive Characteristics

2008 ◽  
Vol 375-376 ◽  
pp. 454-458
Author(s):  
Dao Chun Xu ◽  
Ping Fa Feng ◽  
Jing Feng Zhi ◽  
Ding Wen Yu ◽  
Zhi Jun Wu
Keyword(s):  
High Speed ◽  
Physical Simulation ◽  
Three Dimensional ◽  
Cutting Temperature ◽  
Simulation Models ◽  
Technical Difficulty ◽  
Machining Process ◽  
Processing Efficiency ◽  
High Speed Cutting ◽  
Physics Simulation

The physical simulation of high-speed cutting (HSC) is a hot research in cutting field. Dynamic physical simulation is the key technical difficulty of physical simulation. It can afford the machining process parameters quickly and efficiently, such as cutting stress, cutting temperature, tool wear etc., which have important academic and practical value. The cutting theoretical mathematical model based on the elastic-plastic mechanics and tribology was built up. The two-dimensional / three-dimensional (2D/3D) HSC dynamic physics simulation models were built up by the finite element method. The stress, thermal distribution and tool load etc. during the high speed machining (HSM) was obtained. These parameters provided key technical basis for the establishment and optimization of HSM parameters. They can save much machining experiments cost and improve the processing efficiency.

Control of Machining Process for Titanium Alloy Based on Green Cooling and Lubricating Technology

2012 ◽  
Vol 580 ◽  
pp. 7-11
Author(s):  
Yue Zhang ◽  
Li Han ◽  
You Jun Zhang ◽  
Xi Chuan Zhang
Keyword(s):  
Titanium Alloy ◽  
Water Vapor ◽  
High Speed ◽  
Cutting Temperature ◽  
Small Diameter ◽  
Machining Process ◽  
Machined Surface ◽  
Cutting Zone ◽  
Cutting Experiments ◽  
Special Control

The machining process of titanium alloys always need special control by using coolant and lubricant as it is one of the difficult-to-cut materials. The cutting experiments are carried out based on green cooling and lubricating technology. To achieve green cutting of titanium alloy Ti-6Al-4V with water vapor cooling and lubricating, a minitype generator is developed. Compared to dry and wet cutting, the using of water vapor decreases the cutting force and the cutting temperature respectively; enhances the machined surface. And it can help to chip forming and breaking. Water vapor application also improves Ti-6Al-4V machinability. The excellent cooling and lubricating action of water vapor could be summarized that water molecule has polarity, small diameter and high speed, can be easily and rapidly to proceed adsorption in the cutting zone. The results indicate that the using of water vapor has the potential to attain the green cutting of titanium alloy.

The Application of FEA in High-Speed Cutting Tool

2011 ◽  
Vol 314-316 ◽  
pp. 1258-1261
Author(s):  
Lian Qing Ji ◽  
Kun Liu
Keyword(s):  
Titanium Alloy ◽  
Cutting Force ◽  
High Speed ◽  
Cutting Tool ◽  
Cutting Tools ◽  
Cutting Temperature ◽  
Material Model ◽  
Friction Model ◽  
High Speed Cutting ◽  
Key Technologies

The history and application of the FEA are briefly presented in this paper. Several key technologies such as the building of material model, the establishment of the chip - tool friction model as well as meshing are described. Taking the high-speed cutting of titanium alloy (Ti - 10V - 2Fe - 3Al) as an example , reasonable cutting tools parameters are determined by simulating the influences of cutting temperature, cutting force on the tools parameters using FEA.

Three-Dimensional Relief in Turbomachinery Blading

1990 ◽  
Vol 112 (4) ◽  
pp. 587-596 ◽  
Author(s):  
A. R. Wadia ◽  
B. F. Beacher
Keyword(s):  
High Speed ◽  
Three Dimensional ◽  
Axial Flow ◽  
Leading Edge ◽  
Two Dimensional ◽  
Suction Surface ◽  
Airfoil Surface ◽  
Flow Angle ◽  
Edge Loading ◽  
Cascade Analysis

The leading edge region of turbomachinery blading in the vicinity of the endwalls is typically characterized by an abrupt increase in the inlet flow angle and a reduction in total pressure associated with endwall boundary layer flow. Conventional two-dimensional cascade analysis of the airfoil sections at the endwalls indicates large leading edge loadings, which are apparently detrimental to the performance. However, experimental data exist that suggest that cascade leading edge loading conditions are not nearly as severe as those indicated by a two-dimensional cascade analysis. This discrepancy between two-dimensional cascade analyses and experimental measurements has generally been attributed to inviscid three-dimensional effects. This article reports on two and three-dimensional calculations of the flow within two axial-flow compressor stators operating near their design points. The computational results of the three-dimensional analysis reveal a significant three-dimensional relief near the casing endwall that is absent in the two-dimensional calculations. The calculated inviscid three-dimensional relief at the endwall is substantiated by airfoil surface static pressure measurements on low-speed research compressor blading designed to model the flow in the high-speed compressor. A strong spanwise flow toward the endwall along the leading edge on the suction surface of the airfoil is responsible for the relief in the leading edge loading at the endwall. This radial migration of flow results in a more uniform spanwise loading compared to that predicted by two-dimensional calculations.

Comparison between Nitrogen-Oil-Mist and Air-Oil-Mist Condition when Turning of Hardened Tool Stainless Steel

2014 ◽  
Vol 660 ◽  
pp. 18-22
Author(s):  
Mohamed Handawi ◽  
Amad Elddein Issa Elshwain ◽  
Mohd Yusof Noordin ◽  
Norizah Redzuan ◽  
Denni Kurniawan
Keyword(s):  
High Speed ◽  
Cutting Tools ◽  
Cutting Temperature ◽  
Minimum Quantity Lubrication ◽  
Machining Process ◽  
Dry Cutting ◽  
Nitrogen Gas ◽  
Cutting Zone ◽  
Oil Mist ◽  
Coated Carbide

Minimum quantity lubrication (MQL) or as it’s called semi dry cutting is a technique which spray a small value of lubricant flow rate to the cutting zone area. MQL has been used in many machining process with different cutting tools and workpiece materials due to its green environments and economically advantageous. MQL has become an attractive option to dry and flood cutting in terms of reduce the temperature in the cutting zone and reduce the cost of the product. However, in MQL seems to be machining limited by cutting temperature, because at high speed the effect of oil mist becomes evaporated. Therefore another alternative cooling approach was used with oil mist in this research. This research presents study the performance of nitrogen gas as a coolant and oil mist as lubricant in turning of hardened stainless tool steel (STAVAX ESR) with hardness 48 HRC. Using a gas as coolant with oil mist is a new solution for enhancing machinability. Turning experiments are carried out on CNC turning machine. The cutting insert grade is KC5010 (PVD-TiAlN wiper coated carbide). The experimental results were: 1) nitrogen gas with oil mist prolongs tool life compare with air with oil mist. 2) better product surface finish by using nitrogen gas with oil mist.

Bubble Formation in the Underwater Laser Ablation of Silicon

2016 ◽  
Vol 835 ◽  
pp. 144-148 ◽  
Author(s):  
Wisan Charee ◽  
Viboon Tangwarodomnukun ◽  
Chaiya Dumkum
Keyword(s):  
Laser Beam ◽  
High Speed ◽  
Bubble Formation ◽  
Laser Pulses ◽  
Machining Process ◽  
Laser Machining ◽  
Dynamic Features ◽  
Workpiece Material ◽  
Work Surface ◽  
Underwater Laser

Thermal damage of workpiece material induced by laser machining process can be reduced by using the underwater technique. This method requies the whole workpiece to be submerged in water while a laser beam strikes the work surface for ablation. Though water can cool the workpiece during the ablation, the dynamic features of water can adversely interfere the laser beam. The vapor bubbles created in water can scatter the laser beam and in turn attenuate the laser intensity at the work surface so as the ablation performance. In this paper, the bubble formation caused by laser machining of silicon in water was investigated and analyzed. The shadowgraph technique associated with the high speed camera was used to capture and measure the vapor bubble in water. The bubble size was found to increase with the laser pulse energy. After a number of laser pulses irradiated on the workpiece surface, the bubble was broken up into small ones which can significantly disturb the laser beam so as the ablation performance.

Viscous Throughflow Modeling for Multistage Compressor Design

1993 ◽  
Vol 115 (2) ◽  
pp. 296-304 ◽  
Author(s):  
M. A. Howard ◽  
S. J. Gallimore
Keyword(s):  
Shear Force ◽  
High Speed ◽  
Three Dimensional ◽  
Axial Compressor ◽  
Design System ◽  
Flow Angle ◽  
Axial Compressors ◽  
Dynamic Head ◽  
Viscous Shear ◽  
Compressor Design

An existing throughflow method for axial compressors, which accounts for the effects of spanwise mixing using a turbulent diffusion model, has been extended to include the viscous shear force on the endwall. The use of a shear force, consistent with a no-slip condition, on the annulus walls in the throughflow calculations allows realistic predictions of the velocity and flow angle profiles near the endwalls. The annulus wall boundary layers are therefore incorporated directly into the throughflow prediction. This eliminates the need for empirical blockage factors or independent annulus boundary layer calculations. The axisymmetric prediction can be further refined by specifying realistic spanwise variations of loss coefficient and deviation to model the three-dimensional endwall effects. The resulting throughflow calculation gives realistic predictions of flow properties across the whole span of a compressor. This is confirmed by comparison with measured data from both low and high-speed multistage machines. The viscous throughflow method has been incorporated into an axial compressor design system. The method predicts the meridional velocity defects in the endwall region and consequently blading can be designed that allows for the increased incidence, and low dynamic head, near the annulus walls.

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