Simulation and Study on the Formation Mechanism of Chip Based on Micro Cutting

2016 ◽  
Vol 679 ◽  
pp. 103-106 ◽  
Author(s):  
Qi Ding Li ◽  
Ke Tian Li ◽  
Hai Min Li
Keyword(s):  
Finite Element ◽  
Finite Element Model ◽  
Cutting Force ◽  
Formation Mechanism ◽  
Element Model ◽  
Cutting Mechanism ◽  
Cutting Depth ◽  
Micro Cutting ◽  
Model Based ◽  
Simulation Results

A finite element model based on Abaqus/Explicit is built. Micro cutting mechanism of Al7075 with different cutting depth is simulated and analyzed. The simulation results show that if the cutting depth is more than 10μm, the chip is a kind of continuous curl. If the cutting depth is less than 10μm, the chip is a kind of feathery squeeze debris. When the cutting depth is very small (3μm), the shape of chips is just like discontinuous wrinkle. By contrasting the simulation results of cutting force with its theoretical values, they have the same result. The model of the chip prediction could achieve ideal simulation results.

Cutting performance investigation based on the variable friction model by considering sliding velocity and limiting stress

2020 ◽  
Vol 234 (8) ◽  
pp. 1113-1123
Author(s):  
Xin Li ◽  
Zhenyu Shi ◽  
Ningmin Duan ◽  
Peng Cui ◽  
Shuai Zhang ◽  
...  
Keyword(s):  
Finite Element ◽  
Friction Coefficient ◽  
Finite Element Model ◽  
Cutting Force ◽  
Element Model ◽  
Friction Model ◽  
Rake Face ◽  
Sliding Velocity ◽  
Variable Friction ◽  
Simulation Results

Fast and accurate cutting force prediction is still one of the most complex problems and challenges in the machining research community. In this study, a modified finite element model is presented to predict cutting force and cutting length in turning operations of AISI 1018. Unlike the existing research, in which the mean friction coefficient μ was taken, a variable friction coefficient μ involving the sliding velocity between chip and tool is presented in this article. The sticking–sliding friction model is adopted, and the maximum limiting stress in sticking region is calculated by considering the thermal softening and normal stress distribution. Experiments have been performed for machining AISI 1018 using tungsten carbide tool, and simulation results have been compared to experiments. The simulation results of the modified finite element model have shown better outputs in predicting cutting force, tangential force, and tool–chip contact length on the rake face. The results of this article not only are meaningful to optimize tool design and cutting parameters but also can provide a clear understanding of contact behavior between tool rake face and chip.

Finite Element Model and Analysis for Micro-Cutting of Aluminum Alloy 7050-T7451

2012 ◽  
Vol 566 ◽  
pp. 650-653 ◽  
Author(s):  
Fu Zeng Wang ◽  
Jie Sun ◽  
Pei Qin Sun ◽  
Jun Zhou
Keyword(s):  
Finite Element ◽  
Finite Element Model ◽  
Cutting Force ◽  
Chip Thickness ◽  
Element Model ◽  
Actual State ◽  
Depth Of Cut ◽  
Fe Model ◽  
Uncut Chip Thickness ◽  
Micro Cutting

In this paper, a finite element model with respect to actual state of micro-cutting is established by adopting software of ABAQUS/Explicit. Based on the FE model, the cutting force and specific cutting force with various uncut depth of cut with different cutting edge radius are compared and then analyzed with regard to this simulation. In micro-cutting, the nonlinear scaling phenomenon is more evident with the decreasing of uncut chip thickness. The likely explanations for the size effect in small uncut chip thickness are discussed in this paper.

3D Finite Element Simulation for Turning of Hardened 45 Steel

2019 ◽  
Vol 13 (2) ◽  
pp. 181-188
Author(s):  
Meng Liu ◽  
Guohe Li ◽  
Xueli Zhao ◽  
Xiaole Qi ◽  
Shanshan Zhao
Keyword(s):  
Finite Element ◽  
Finite Element Model ◽  
Cutting Force ◽  
Finite Element Simulation ◽  
Orthogonal Experiment ◽  
Element Model ◽  
3D Finite Element ◽  
Element Simulation ◽  
Metal Machining ◽  
Single Factor Experiment

Background: Finite element simulation has become an important method for the mechanism research of metal machining in recent years. Objective: To study the cutting mechanism of hardened 45 steel (45HRC), and improve the processing efficiency and quality. Methods: A 3D oblique finite element model of traditional turning of hardened 45 steel based on ABAQUS was established in this paper. The feasibility of the finite element model was verified by experiment, and the influence of cutting parameters on cutting force was predicted by single factor experiment and orthogonal experiment based on simulation. Finally, the empirical formula of cutting force was fitted by MATLAB. Besides, a lot of patents on 3D finite element simulation for metal machining were studied. Results: The results show that the 3D oblique finite element model can predict three direction cutting force, the 3D chip shape, and other variables of metal machining and the prediction errors of three direction cutting force are 5%, 9.02%, and 8.56%. The results of single factor experiment and orthogonal experiment are in good agreement with similar research, which shows that the model can meet the needs for engineering application. Besides, the empirical formula and the prediction results of cutting force are helpful for the parameters optimization and tool design. Conclusion: A 3D oblique finite element model of traditional turning of hardened 45 steel is established, based on ABAQUS, and the validation is carried out by comparing with experiment.

scholarly journals Investigation of the Thickness Differential on the Formability of Aluminum Tailor Welded Blanks

Metals ◽  
2021 ◽  
Vol 11 (6) ◽  
pp. 875
Author(s):  
Jie Wu ◽  
Yuri Hovanski ◽  
Michael Miles
Keyword(s):  
Experimental Data ◽  
Finite Element ◽  
Numerical Model ◽  
Plastic Strain ◽  
Finite Element Model ◽  
Equivalent Plastic Strain ◽  
Element Model ◽  
Dome Height ◽  
Tailor Welded Blanks ◽  
Simulation Results

A finite element model is proposed to investigate the effect of thickness differential on Limiting Dome Height (LDH) testing of aluminum tailor-welded blanks. The numerical model is validated via comparison of the equivalent plastic strain and displacement distribution between the simulation results and the experimental data. The normalized equivalent plastic strain and normalized LDH values are proposed as a means of quantifying the influence of thickness differential for a variety of different ratios. Increasing thickness differential was found to decrease the normalized equivalent plastic strain and normalized LDH values, this providing an evaluation of blank formability.

scholarly journals Reconstruction finite element model of cars

2021 ◽  
Vol 4 (1) ◽  
pp. first
Author(s):  
Lý Hùng Anh ◽  
Nguyễn Phụ Thượng Lưu ◽  
Nguyễn Thiên Phú ◽  
Trần Đình Nhật
Keyword(s):  
Finite Element ◽  
Finite Element Model ◽  
Element Model ◽  
Finite Element Models ◽  
Crash Analysis ◽  
Inertia Moment ◽  
Frontal Crash ◽  
Analysis Center ◽  
Simulation Results ◽  
And Behavior

The experimental method used in a frontal crash of cars costs much time and expense. Therefore, numerical simulation in crashworthiness is widely applied in the world. The completed car models contain a lot of parts which provided complicated structure, especially the rear of car models do not contribute to behavior of frontal crash which usually evaluates injuries of pedestrian or motorcyclist. In order to save time and resources, a simplification of the car models for research simulations is essential with the goal of reducing approximately 50% of car model elements and nodes. This study aims to construct the finite element models of front structures of vehicle based on the original finite element models. Those new car models must be maintained important values such as mass and center of gravity position. By using condition boundaries, inertia moment is kept unchanged on new model. The original car models, which are provided by the National Crash Analysis Center (NCAC), validated by using results from experimental crash tests. The modified (simplistic) vehicle FE models are validated by comparing simulation results with experimental data and simulation results of the original vehicle finite element models. LS-Dyna software provides convenient tools and very strong to modify finite element model. There are six car models reconstructed in this research, including 1 Pick-up, 2 SUV and 3 Sedan. Because car models were not the main object to evaluate in a crash, energy and behavior of frontal part have the most important role. As a result, six simplified car models gave reasonable outcomes and reduced significantly the number of nodes and elements. Therefore, the simulation time is also reduced a lot. Simplified car models can be applied to the upcoming frontal simulations.

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