Finite Element Simulation of Chip Formation with Single Grain

2009 ◽  
Vol 416 ◽  
pp. 210-215 ◽  
Author(s):  
Wan Shan Wang ◽  
Chong Su ◽  
Zi Rui Pang ◽  
Jun Ming Hou
Keyword(s):  
Three Dimensional ◽  
Cutting Temperature ◽  
Material Flows ◽  
Lagrange Method ◽  
Workpiece Material ◽  
Edge Angle ◽  
Abrasive Grain ◽  
Element Simulation ◽  
Single Grain ◽  
Simulation Results

Three-dimensional cutting process of single grain in the shape of polygonal pyramid was simulated by coupled Euler-Lagrange method. The method makes the workpiece material free from its meshes. The material allowance can be removed without mesh separation criterion. The simulation results show that workpiece material flows to the side and front owing to the pressing of cutting plane. Chip flows out along the front of the grain upward. The deformation of workpiece material contacted with grain edge is very severe. Therefore there is large machining stress concentration at the contact zone of grain edge. It results in biggish residual stress and cutting temperature at the side and bottom of the groove. The contact stress at edge angle of abrasive grain is biggest. Therefore grain wear is severe in the position

Dynamic Analysis and Three-Dimensional Finite Element Simulation of Cracked Gear

2007 ◽  
Vol 353-358 ◽  
pp. 1072-1077 ◽  
Author(s):  
Ren Ping Shao ◽  
Xin Na Huang ◽  
Pu Rong Jia ◽  
Wan Lin Guo ◽  
Kaoru Hirota
Keyword(s):  
Fault Diagnosis ◽  
Gear Tooth ◽  
Three Dimensional ◽  
Dynamic Features ◽  
Cracked Beam ◽  
Element Simulation ◽  
Dimensional Finite Element ◽  
Simulation Results ◽  
Three Dimensional Finite Element ◽  
Good Agreement

A method of damage detection and fault diagnosis for gears is presented based on the theory of elastomeric dynamics according to the theory of cracked beam. It takes an advantage of accurate fault diagnosis of gear body using the change of dynamic features and has some advantages for dynamic design of gear systems.The dynamics characteristics, i.e., natural frequency, vibration shape,dynamic response and so on, due to crack of gear tooth are studied, and the gear dynamics characteristics caused by the position and size of crack are deeply investigated by comparison with FEM. The theoretical analysis results are contrasted with numerical simulation results and shows good agreement with the result by FEM. The proposed method can be used to detect damage and diagnose fault for gear structures and also can be applied to designing dynamic characteristics for gear systems.

Finite Element Simulation of Quick – Stop Experiments for Better Understanding of Chip Formation in Grinding

2011 ◽  
Vol 223 ◽  
pp. 764-773 ◽  
Author(s):  
Hans Werner Hoffmeister ◽  
Arne Gerdes
Keyword(s):  
Finite Element ◽  
Chip Formation ◽  
Orthogonal Cutting ◽  
Cutting Speed ◽  
Element Model ◽  
Rake Angle ◽  
Grinding Process ◽  
Workpiece Material ◽  
Element Simulation ◽  
Single Grain

Several authors have previously simulated chip formation and their behaviour at the orthogonal cutting process. In contrast the chip formation for grinding was less investigated. This paper introduces a quick-stop device which allows easy investigation of the chip formation for the grinding process. For this process a workpiece forced by compressed air is shot against a single grain diamond with a large negative rake angle. Cutting forces were measured with a piezo electric sensor and discussed for a cutting speed range from 10m/s up to 30m/s. In Abaqus/Explicit a lagrangian formulation based finite element model was built to describe the chip formation for the grinding process. Chip formation, stress and heat distribution in the workpiece material can be calculated by this simulation model. The material behaviour was described with the Johnson Cook law. The simulation results show a good correlation compared to the quick stop experiments. All in all this simulation leads to a better understanding of the chip formation during grinding.

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.

Research on the Grinding Mechanism Based on the Cutting Simulation

2012 ◽  
Vol 510 ◽  
pp. 395-400
Author(s):  
Hong Xia Zhang ◽  
Wu Yi Chen
Keyword(s):  
Temperature Distribution ◽  
Material Removal ◽  
Operation Research ◽  
Cutting Temperature ◽  
Stress Fields ◽  
Mechanical Coupling ◽  
Abrasive Grain ◽  
Grinding Mechanism ◽  
Cutting Zone ◽  
Simulation Results

Grinding of metals is a complex material removal operation. Research on cutting process of a single abrasive grain is the basis of further understanding of grinding mechanism. In this investigation, the simulation and analysis for the non-uniform thermo-mechanical coupling intense stress fields in cutting zones of a single abrasive with negative rake are conducted by means of the FEM techniques. The cutting forces, the cutting temperature distribution and the strain rate in cutting zone are numerically demonstrated. Grinding mechanics are analyzed from microscopic view according to the simulation results. Research results facilitate a better understanding on the mechanics of grinding.

CBN-Kornverschleißmodellierung/Numerical modeling of CBN grain wear during single grain engagement – CBN-grain wear modelling

2021 ◽  
Vol 111 (06) ◽  
pp. 414-418
Author(s):  
Marc Bredthauer ◽  
Patrick Mattfeld ◽  
Sebastian Barth ◽  
Thomas Bergs
Keyword(s):  
Numerical Modeling ◽  
Three Dimensional ◽  
The Finite Element Method ◽  
Finite Elemente ◽  
Wear Modelling ◽  
Numerische Modellierung ◽  
Finite Elemente Methode ◽  
Single Grain ◽  
Simulation Results ◽  
First Time

Dieser Beitrag stellt die numerische Modellierung des CBN-Kornverschleißes beim Einkorneingriff mit der Finite-Elemente-Methode vor. Es wird erstmalig eine dreidimensionale Verschleißsimulation unter Verwendung realer CBN- Korngeometrien im Korn-Werkstückkontakt durchgeführt. Dazu werden drei reale Korngeometrien simuliert, um die Verschleißmechanismen des realen Korneingriffs abzubilden. Abschließend werden die Simulationsergebnisse mit empirischen Untersuchungen verglichen.   This article is about the numerical modeling of CBN grain wear in single grain engagement using the finite element method. A three-dimensional wear simulation using real CBN grain geometries in grain-workpiece contact is conducted for the first time. For this purpose, three real grain geometries are simulated to represent the wear mechanisms of the real grain engagement. Finally, the simulation results are compared with empirical investigations.

Design of finite-time guidance law based on observer and head-pursuit theory

2021 ◽  
pp. 095441002098456
Author(s):  
Chenqi Zhu
Keyword(s):  
Finite Time ◽  
Three Dimensional ◽  
Hypersonic Vehicle ◽  
Two Dimensional ◽  
Dimensional Model ◽  
Reaching Law ◽  
Guidance Law ◽  
Fast Power ◽  
Simulation Results ◽  
Guidance Laws

In order to improve the guiding accuracy in intercepting the hypersonic vehicle, this article presents a finite-time guidance law based on the observer and head-pursuit theory. First, based on a two-dimensional model between the interceptor and target, this study applies the fast power reaching law to head-pursuit guidance law so that it can alleviate the chattering phenomenon and ensure the convergence speed. Second, target maneuvers are considered as system disturbances, and the head-pursuit guidance law based on an observer is proposed. Furthermore, this method is extended to a three-dimensional case. Finally, comparative simulation results further verify the superiority of the guidance laws designed in this article.

Simulation of Machining of Incoloy 907 Based on Thermodynamical Constitutive Equation

2013 ◽  
Vol 631-632 ◽  
pp. 681-685
Author(s):  
Fang Shao ◽  
Fa Qing Li ◽  
Hai Ying Zhang ◽  
Xuan Gao
Keyword(s):  
Cutting Force ◽  
Cutting Temperature ◽  
Tool Material ◽  
High Reactivity ◽  
Good Prediction ◽  
Workpiece Material ◽  
Element Analysis ◽  
Good Prediction Accuracy ◽  
Experimental Cutting ◽  
Cutting Tool Materials

Aero-engine alloys (also as known as superalloys)are known as difficult-to-machine materials, especially at higher cutting speeds, due to their several inherent properties such as low thermal conductivity and their high reactivity with cutting tool materials. In this paper a finite element analysis (FEA) of machining for Incoloy907 is presented. In particular, the thermodynamical constitutitve equation(T-C-E) in FEA is applied for both workpiece material and tool material. Cutting temperature and cutting force are predicted. The comparison between the predicted and experimental cutting temperature and cutting force are presented and discussed. The results indicated that a good prediction accuracy of both principal cutting temperature and cutting force can be achieved by the method of FEA with thermodynamical constitutitve equation.

Direct simulation of evolution and control of three-dimensional instabilities in attachment-line boundary layers

1995 ◽  
Vol 291 ◽  
pp. 369-392 ◽  
Author(s):  
Ronald D. Joslin
Keyword(s):  
Boundary Layer ◽  
Stokes Equations ◽  
Three Dimensional ◽  
Plate Boundary ◽  
Navier Stokes ◽  
Two Dimensional ◽  
Computationally Efficient ◽  
Simulation Results ◽  
Dimensional Simulation ◽  
Attachment Line

The spatial evolution of three-dimensional disturbances in an attachment-line boundary layer is computed by direct numerical simulation of the unsteady, incompressible Navier–Stokes equations. Disturbances are introduced into the boundary layer by harmonic sources that involve unsteady suction and blowing through the wall. Various harmonic-source generators are implemented on or near the attachment line, and the disturbance evolutions are compared. Previous two-dimensional simulation results and nonparallel theory are compared with the present results. The three-dimensional simulation results for disturbances with quasi-two-dimensional features indicate growth rates of only a few percent larger than pure two-dimensional results; however, the results are close enough to enable the use of the more computationally efficient, two-dimensional approach. However, true three-dimensional disturbances are more likely in practice and are more stable than two-dimensional disturbances. Disturbances generated off (but near) the attachment line spread both away from and toward the attachment line as they evolve. The evolution pattern is comparable to wave packets in flat-plate boundary-layer flows. Suction stabilizes the quasi-two-dimensional attachment-line instabilities, and blowing destabilizes these instabilities; these results qualitatively agree with the theory. Furthermore, suction stabilizes the disturbances that develop off the attachment line. Clearly, disturbances that are generated near the attachment line can supply energy to attachment-line instabilities, but suction can be used to stabilize these instabilities.

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