Study of 6061 Aluminum Alloy Milling Using Four-Blade Face Cutter

2015 ◽  
Vol 661 ◽  
pp. 62-68
Author(s):  
Dyi Cheng Chen ◽  
Ci Syong You ◽  
Chia An Tu ◽  
Chieh Hsin Ni
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Aluminum Alloy ◽  
Effective Strain ◽  
Cutting Speed ◽  
Face Milling ◽  
Element Analysis ◽  
Milling Cutter ◽  
The Finite Element Analysis ◽  
Tool Types

In this paper, construction of finite element analysis based on DEFORMTM 3D four-blade face milling cutter aluminum 6061 cutting, explore the finite element analysis of face milling cutter rotating in a circle cutting of aluminum alloy 6061.Tool types used WC milling cutters, cutting speed, feed rate as fixed process parameters. The study analyzed four rotations of the blade face milling chip formation, effective stress, effective strain and material changes in temperature and tool wear.

Study on the cavity closure behavior of steel ingots during open die forging

2019 ◽  
Vol 233 (13) ◽  
pp. 2447-2457
Author(s):  
Yongchul Kwon ◽  
Sangsik Kim ◽  
Jonghun Kang
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Theoretical Basis ◽  
Effective Strain ◽  
Element Analysis ◽  
Large Steel ◽  
The Finite Element Analysis ◽  
Cavity Closure ◽  
Steel Ingots ◽  
Open Die Forging

The manufacturing of sound forgings from large steel ingots requires that internal cavity defects generated during the steel ingot solidification process be compressed by open die forging. The forging ratio that is generally recommended to remove internal defects in large forged products is 3S (threefold); however, the practice lacks a theoretical basis. In this study, a forging experiment and a finite element analysis were performed to investigate the correlation between the forging ratio for large steel ingots (3S) and the cavity closure behavior. First, a hot compression experiment was performed by varying the temperature and strain rate, and the flow stress data observed in the experiment was applied to the finite element analysis. In the experiment for the cogging process, the forging ratio was applied to an actual non-compressive defect material. The finite element analysis was performed using the same forging path as the forging experiment. In the cogging experiment, cavity closure was found by ultrasonic inspection at the forging ratio of 2.9S. The finite element analysis showed that the size of the cavity was significantly decreased at the forging ratio of 2.9S. A finite element analysis was also performed to investigate effective strain and hydrostatic stress at the forging ratio of 2.9S. Finally, this article provides the theoretical basis for the limitation of the internal defect size in initial materials, the threshold effective strain, and the limiting forging ratio of forged products to ensure the internal soundness of large forged products.

The Finite-Element Analysis of Cylindrical Helical Tooth Milling Cutter Based on Marc

2011 ◽  
Vol 52-54 ◽  
pp. 1147-1152
Author(s):  
Guang Guo Zhang ◽  
Wei Jiang ◽  
Hong Hua Zhang ◽  
Huan Wang
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Cutting Forces ◽  
Element Model ◽  
Local Deformation ◽  
Analysis Software ◽  
Element Analysis ◽  
Milling Cutter ◽  
Cutter Life ◽  
The Finite Element Analysis

In the traditional designs of milling cutter, we cannot get the required accuracy of machining as there may be local deformation on the edges, even more the cutter can break down. Aiming at this situation, a finite-element model of straight pin milling cutter with helical tooth are built using Marc, a nonlinear finite-element analysis software, the different cutting forces of the milling cutter during the cutting process are analyzed and the cutting forces of the milling cutter at different parameters are studied. We get the stress, the strain and the temperature distribution of the milling cutter in different situation. Our work offer a theoretical basis of improving stress of the cutter, designing the structure of cutters reasonably and analyzing the cutter failure as well as a new method of analysis and calculation of the cutter life and strength.

Study on the machining distortion of aluminum alloy parts induced by forging residual stresses

2016 ◽  
Vol 231 (4) ◽  
pp. 618-627 ◽  
Author(s):  
Liangbao Liu ◽  
Jianfei Sun ◽  
Wuyi Chen ◽  
Pengfei Sun
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Aluminum Alloy ◽  
Residual Stresses ◽  
Material Removal ◽  
Actual Condition ◽  
Element Analysis ◽  
The Finite Element Analysis ◽  
Layer Removal Method ◽  
Analytical Correction

A weak-rigid monolithic component is subjected to significant distortion after the removal of material. This condition is principally due to flexibility of the part and the release of initial residual stresses resulting from fabrication. This article reports a systematic study on the measurement of initial residual stresses and the distortion of a windshield frame part induced by material removal from the forged blanks of aluminum alloy 7085-T7452. A layer-removal method was employed to measure the stress profiles of the blank. The stresses after analytical correction were found to be closer to actual condition. The effect of material removal on distortion from stressed blank was investigated using the finite element analysis software ANSYS. The simulated results indicate that after the proportion of removed material exceeds 60%, part distortion becomes stable. The comparisons of the simulation with experimental data suggest sufficient agreement with conclusion that the use of finite element analysis proves to be an attractive and reliable method for predicting stress-induced distortion.

Optimization of Axial Rake Angle for Face Milling Using Taguchi Method and Finite Element Analysis

2013 ◽  
Vol 465-466 ◽  
pp. 746-750 ◽  
Author(s):  
Mohd Riduan Ibrahim ◽  
A.R. Abd. Kadir ◽  
M.S. Omar ◽  
M.H. Osman ◽  
S. Sulaiman ◽  
...  
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Optimal Parameter ◽  
Signal To Noise Ratio ◽  
Cutting Speed ◽  
Rake Angle ◽  
Milling Process ◽  
Face Milling ◽  
Element Analysis ◽  
Confirmation Test

This study employed the Taguchi approach in combination with finite element analysis (DEFORM3D) to investigate face milling process onto AL6061. The factors studied in this investigation were cutting speed, feed rate, and axial rake angle. The simulation of flank wear was generated according to Usuis wear model though the L9(34) of the orthogonal array experiment. ANOVA analysis and F test were conducted to find the significant factor that contributes to tool wear in the signal to noise ratio. Finally, the confirmation test has been carried out at optimal parameter.

FINITE ELEMENT ANALYSIS OF DEFORMATION CHARACTERISTICS IN HEAVY SLAB ROLLING

2009 ◽  
Vol 23 (06n07) ◽  
pp. 1591-1596 ◽  
Author(s):  
YO-HAN JI ◽  
JONG-JIN PARK ◽  
CHANG-HO MOON ◽  
MYUNG-SHIK CHUN ◽  
HAE-DOO PARK
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Hydrostatic Stress ◽  
Effective Strain ◽  
Middle Layer ◽  
Element Analysis ◽  
Cylindrical Pore ◽  
Pressure Distributions ◽  
The Finite Element Analysis ◽  
Pore Closure

Plastic deformation that occurs in a heavy slab during plane-strain rolling was investigated by the finite element analysis. A cylindrical pore was assumed to be located along the transverse direction of a slab. The effective strain was found to be the largest at the sub-surface layer and the smallest at the middle layer, where the shear strain developed the least. Pore closure was most difficult at the middle layer. This is where hydrostatic stress in addition to effective strain developed the least. Rolling torques, rolling forces and pressure distributions at the roll/slab interface were investigated as well, under various conditions.

To Research Residual Stress Using Finite Element Analysis

2012 ◽  
Vol 525-526 ◽  
pp. 105-108
Author(s):  
Zhe Feng Wang ◽  
Yao Yang Hu
Keyword(s):  
Residual Stress ◽  
Finite Element Analysis ◽  
Finite Element ◽  
Aluminum Alloy ◽  
Stress Distributions ◽  
Element Analysis ◽  
Thick Plates ◽  
The Finite Element Analysis ◽  
Quench Hardening ◽  
Theoretical Analyses

The residual stress distributions of 7075 aluminum alloy rectangular thick plates after quench-hardening had been simulated firstly, then all the results were presented and compared with each other. Some deep theoretical analyses were also carried out. The results show that complicated residual stress distribution regularities in aluminum alloy thick plates can be obtained by the finite element analysis successfully.

Friction Factor of 6061 Aluminum Alloy and Application to the Finite Element Analysis of Wheel Forging

2017 ◽  
Vol 739 ◽  
pp. 231-234
Author(s):  
Tung Sheng Yang ◽  
Kui Chih Luo
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Aluminum Alloy ◽  
Friction Factor ◽  
Testing Machine ◽  
Element Analysis ◽  
6061 Aluminum Alloy ◽  
The Finite Element Analysis ◽  
Different Temperatures ◽  
Material Testing Machine

The friction factor between 6061 aluminum alloy and die material (SKD61) are determined at different temperatures by using ring compression test which are carried out on a material testing machine. Mechanical properties and fiction factor are then applied to the finite element analysis of the wheel forging for different elevated temperature. Maximum forging load, effective stress and temperature distribution are determined of the wheel forging, using the finie element analysis. Finally, the wheel parts are formed by the forging machine under the conditions using finite element analysis.

Finite Element Analysis of Rim Ring Rolling Forming of Bicycle Aluminum Alloy

2012 ◽  
Vol 445 ◽  
pp. 231-236
Author(s):  
Dyi Cheng Chen ◽  
Bao Yan Lai ◽  
Ci Syong You
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Aluminum Alloy ◽  
Effective Strain ◽  
Rolling Process ◽  
Ring Rolling ◽  
Rigid Plastic ◽  
Element Analysis ◽  
Rolling Velocity ◽  
Plastic Deformation Behavior

The bicycle is not only a pollution-free method of transportation, but also has sport and recreation functions. Therefore, the bicycle attracted attention in now society gradually. This study uses the rigid-plastic finite element (FE) DEFORMTM software to investigate the plastic deformation behavior of a 7075 aluminum alloy workpiece as it is formed through a ring rolling die. This study systematically investigates the relative influences of ring rolling velocity, entering velocity, and workpiece temperature under various ring rolling forming conditions. The effective strain, effective stress, and workpiece damage distribution in the ring rolling process are also investigated. Results confirm the suitability of the proposed design process, which allows a ring rolling manufacturer to achieve a perfect design during finite element analysis.

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