Finite Element Analysis of Micro-Cutting Aluminum 7050-T7451 with the Tool Edge Radius Considered

2010 ◽  
Vol 443 ◽  
pp. 663-668 ◽  
Author(s):  
Jun Zhou ◽  
Jian Feng Li ◽  
Jie Sun
Keyword(s):  
Finite Element ◽  
Plastic Strain ◽  
Cutting Temperature ◽  
Machining Process ◽  
Micro Machining ◽  
Element Analysis ◽  
Micro Cutting ◽  
Tool Edge Radius ◽  
Edge Radius ◽  
Tool Edge

In this paper, a series of simulation works by finite element method for predicting the temperature and the plastic strain distributions in micro cutting process with the tool edge radius considered were conducted. The workpiece is Aluminum alloy 7050-T7451 and its flow stress is taken as a function of strain, strain rate and temperature in order to reflect realistic behavior in machining process. From the simulation works, a lot of information on the micro-machining process can be obtained, such as cutting force, cutting temperature, distributions of temperature and plastic strain, etc. In addition, explanations for the observed trends are also given.

Finite Element Analysis of Cutting Force and Burr Formation in Micro-Cutting of Titanium Alloy Considering Tool Edge Radius

2012 ◽  
Vol 426 ◽  
pp. 235-238 ◽  
Author(s):  
Da Peng Dong ◽  
Xiao Hu Zheng ◽  
Ming Chen ◽  
Qing Long An
Keyword(s):  
Cutting Force ◽  
Simulation Modeling ◽  
Burr Formation ◽  
Element Analysis ◽  
Micro Cutting ◽  
Tool Edge Radius ◽  
Cutting Energy ◽  
Burr Size ◽  
Edge Radius ◽  
Tool Edge

In recent years, with the development of machinery industry, micro-cutting technologies have been gradually moving into engineering realization. The paper carries out a series of works on simulation modeling of micro-cutting of Ti-5Al-5V-5Mo-3Cr considering tool edge radius. Unlike conventional cutting, in micro-cutting the effect of tool edge radius which has a marked impact on cutting force, specific cutting energy, burr formation and burr size can no longer be neglected.

Finite Element Modeling for High Speed Machining of Ti-6Al-4V Using ALE Boundary Technology

2011 ◽  
Vol 66-68 ◽  
pp. 1509-1514
Author(s):  
Dong Lu ◽  
Ming Ming Yang ◽  
Hong Fu Huang ◽  
Xiao Hong Zhong
Keyword(s):  
Finite Element ◽  
Finite Element Model ◽  
High Speed ◽  
Element Model ◽  
Machining Process ◽  
Computational Time ◽  
High Speed Machining ◽  
Tool Edge Radius ◽  
Edge Radius ◽  
Tool Edge

A finite element model of HSM (High Speed Machining) process of Ti6Al4V was developed with Abaqus 6.10. The flow stress of Ti6Al4V is taken as a function of strain, strain rate and temperature. Considering the fact that the tool edge radius is relatively large in HSM of Ti6Al4V and significantly influences the mechanical behaviour, thus a new Arbitrary Lagrangian-Eulerian (ALE) boundary technology was incorporated into the finite element model to simulate the flowing material around the tool edge.The adoption of ALE boundary technology could avoid using the traditional chip separation criterias and element deletion method in the model, which at the same time results in the less excessive element distortion and computational time in comparison with traditional finite element models of cutting process. The simulation results of Cutting force and temperature close to the experimental values in an acceptable range could be obtained and a stagnant zone in front of the tool edge was successfully observed in this new developed model with large tool edge radius.

Temperature Field Numerical Analysis of Machining Process Based on the Finite Element Analysis

2014 ◽  
Vol 621 ◽  
pp. 611-616 ◽  
Author(s):  
Yan Juan Hu ◽  
Yao Wang ◽  
Zhan Li Wang
Keyword(s):  
Finite Element ◽  
Temperature Field ◽  
Metal Cutting ◽  
Orthogonal Cutting ◽  
Cutting Temperature ◽  
Cutting Parameters ◽  
Element Model ◽  
Machining Process ◽  
Element Analysis ◽  
Mechanical Coupling

In order to study the temperature field distribution in the process of machining, the finite element theory was used to establish the orthogonal cutting finite element model, and the key technologies were discussed simultaneously. By using ABAQUS software for cutting AISI1045 steel temperature field of numerical simulation, the conclusion about changing rule of cutting temperature field can be gotten. The results show that this method can efficiently simulate the distribution of temperature field of the workpiece, cutter and scraps, which is effected by thermo-mechanical coupling in metal work process. It provides the theory evidence for the intensive study of metal-cutting principle, optimizing cutting parameters and improving processing technic and so on.

An Analytical Model for the Prediction of Minimum Chip Thickness in Micromachining

2005 ◽  
Vol 128 (2) ◽  
pp. 474-481 ◽  
Author(s):  
X. Liu ◽  
R. E. DeVor ◽  
S. G. Kapoor
Keyword(s):  
Analytical Model ◽  
Chip Thickness ◽  
Machining Process ◽  
Thickness Effect ◽  
Uncut Chip Thickness ◽  
Minimum Chip Thickness ◽  
Tool Edge Radius ◽  
Edge Radius ◽  
Tool Edge ◽  
Cutting Velocity

In micromachining, the uncut chip thickness is comparable or even less than the tool edge radius and as a result a chip will not be generated if the uncut chip thickness is less than a critical value, viz., the minimum chip thickness. The minimum chip thickness effect significantly affects machining process performance in terms of cutting forces, tool wear, surface integrity, process stability, etc. In this paper, an analytical model has been developed to predict the minimum chip thickness values, which are critical for the process model development and process planning and optimization. The model accounts for the effects of thermal softening and strain hardening on the minimum chip thickness. The influence of cutting velocity and tool edge radius on the minimum chip thickness has been taken into account. The model has been experimentally validated with 1040 steel and Al6082-T6 over a range of cutting velocities and tool edge radii. The developed model has then been applied to investigate the effects of cutting velocity and edge radius on the normalized minimum chip thickness for various carbon steels with different carbon contents and Al6082-T6.

Analyzing the effect of tool edge radius on cutting temperature in micro-milling process

2010 ◽  
Author(s):  
Y. C. Liang ◽  
K. Yang ◽  
K. N. Zheng ◽  
Q. S. Bai ◽  
W. Q. Chen ◽  
...  
Keyword(s):  
Cutting Temperature ◽  
Milling Process ◽  
Micro Milling ◽  
Tool Edge Radius ◽  
Edge Radius ◽  
Tool Edge

A Study of Exit-Burr Formation Mechanism Using the Finite Element Method in Micro-Cutting of Aluminum Alloy

2008 ◽  
Vol 375-376 ◽  
pp. 470-473 ◽  
Author(s):  
Dong Lu ◽  
Jian Feng Li ◽  
Yi Ming Rong ◽  
Jie Sun ◽  
Jun Zhou ◽  
...  
Keyword(s):  
Cutting Speed ◽  
Chip Thickness ◽  
Burr Formation ◽  
Uncut Chip Thickness ◽  
Micro Cutting ◽  
Tool Edge Radius ◽  
Edge Radius ◽  
Tool Edge ◽  
Speed Effect ◽  
Exit Burr

A burr formation process in micro-cutting of Al7075-T7451 was analyzed. Three stages of burr formation including steady-state cutting stage, pivoting stage, and burr formation stage are investigated. And the effects of uncut chip thickness, cutting speed and tool edge radius on the burr formation are studied. The simulation results show that the generation of negative shear zone is one of the prime reasons for burr formation. Uncut chip thickness has a significant effect on burr height; however, the cutting speed effect is minor. Unlike in conventional cutting, in micro-cutting the effect of tool edge radius on the burr geometry can no longer be neglected.

scholarly journals Chatter Behavior in the Milling Process of Inconel 718: Effects of Tool Edge Radius

2018 ◽  
Vol 202 ◽  
pp. 02006
Author(s):  
C H Hoe ◽  
M M Reddy ◽  
V C C Lee ◽  
S Debnath
Keyword(s):  
Inconel 718 ◽  
Elevated Temperatures ◽  
Milling Process ◽  
Machining Process ◽  
Chatter Vibration ◽  
End Mill ◽  
Tool Edge Radius ◽  
Edge Radius ◽  
Tool Edge ◽  
Variable Helix

Inconel 718 is widely used in various high end industries such as aerospace, nuclear plant, petrochemical plants etc. Inconel 718 is used for these applications due to unique mechanical properties such as high mechanical strength at elevated temperatures, high resistance to corrosion, and high strength to weight ratio. The unique properties of Inconel 718 made it difficult to be machined due to rapid work hardening and high cutting temperature. In addition, chatter vibration further increases the difficulty in machining of Inconel 718. In this paper, an experimental study on the effects of tool edge radius to the chatter behaviour was investigated. The dynamic responses of the milling process were recorded and analysed in both time domain and frequency domain. The results showed the variable helix and pitch end mill tool with larger tool edge radius able to mitigate chatter vibration at lower cutting speeds. Variable helix and pitch end mill with specific tool edge radius able to mitigate chatter vibration under the same cutting parameters. Experiments shows proper selection of tool edge radius improves the stability of end milling machining process.

Sign in / Sign up

Export Citation Format

Share Document