Finite Element Simulation of High-Speed Cutting Alloy Cast Iron

2006 ◽  
Vol 532-533 ◽  
pp. 749-752 ◽  
Author(s):  
Jing Kui Ruan ◽  
Ying Lin Ke ◽  
Hui Yue Dong ◽  
Yong Yang
Keyword(s):  
Finite Element ◽  
Cast Iron ◽  
Finite Element Model ◽  
High Speed ◽  
High Strain ◽  
Cutting Temperature ◽  
Element Model ◽  
High Speed Cutting ◽  
Alloy Cast Iron ◽  
Alloy Cast

A finite element model (FEM) of high-speed cutting was built to study the mechanism of high-speed machining of alloy cast iron used widely in auto panel dies. The mechanics properties of workpiece material were obtained in the conditions of high strain-rate, high temperature and high strain through high-speed impact compress experiments. Several key technologies are studied such as friction and chip-tool heat conduction. The cutting temperature, stress distribution, and the chip formation process in the process of high-speed cutting alloy cast iron were analyzed based on the finite element model, which was validated through cutting force experiments. It shows that the FEM can simulate the high-speed cutting process of alloy cast iron materials.

Effect Residual Stress on Material Hardness by Finite Element Simulation during the Process of High Speed Cutting

2016 ◽  
Vol 719 ◽  
pp. 23-27
Author(s):  
De Weng Tang ◽  
Zhi Feng He ◽  
Xi Jian Lv ◽  
Cong Peng
Keyword(s):  
Residual Stress ◽  
Finite Element ◽  
Residual Stresses ◽  
High Speed ◽  
Cutting Temperature ◽  
Element Model ◽  
Residual Tensile Stress ◽  
Machined Surface ◽  
High Speed Cutting ◽  
Material Hardness

Residual stresses induced during the process of high speed cutting are very critical due to safety and corrosion resistance. Based on the nonlinear finite element code DEFORM, thermodynamic couple model of residual stress was built. Effect distribution of residual stresses on three different materials physical properties of hardness are analyzed by using the finite element model during the process of high speed cutting. The results show that metal material hardness is the key factors to residual stress. When materials’ hardness is higher, residual tensile stress is easy to form on the machined surface due to high cutting temperature, such as hardened steel SKD11(HRC=62). To lower hardness material, residual compressive stress is generated on the machined surface for plastic deformation, such as softer materials 7075Al (HRC=23).

The Finite Element Analysis of Serrated Chip Formation in High-Speed Cutting Auto Panel Dies

2008 ◽  
Vol 575-578 ◽  
pp. 293-298 ◽  
Author(s):  
Jing Kui Ruan ◽  
Ying Lin Ke ◽  
Yong Yang
Keyword(s):  
Finite Element ◽  
Cast Iron ◽  
High Speed ◽  
Machining Process ◽  
Contact Friction ◽  
Machining Parameters ◽  
Serrated Chip ◽  
Element Analysis ◽  
Alloy Cast Iron ◽  
Alloy Cast

On the base of analyzing material constitutive model, chip-tool contact friction, and chip separation and fracture, a finite element model (FEM) was built to study the high-speed machining process of alloy cast-iron. The shaping process of serrated chip in high-speed milling alloy cast-iron was simulated and analyzed in detail. It was shown that machining parameters affect the serrated chip forming greatly. The model can be used to optimize machining parameters, prolong tool life and improve machining surface quality.

Numerical Simulation of High Speed Machining of Alloy Cast Iron

2012 ◽  
Vol 468-471 ◽  
pp. 2310-2314
Author(s):  
Yang Tan ◽  
Yi Lin Chi ◽  
Ya Yu Huang ◽  
Ting Qiang Yao
Keyword(s):  
Cast Iron ◽  
High Speed ◽  
Cutting Speed ◽  
Chip Morphology ◽  
Element Model ◽  
Material Behavior ◽  
High Speed Machining ◽  
Alloy Steels ◽  
Alloy Cast Iron ◽  
Alloy Cast

High speed milling of hard alloy steels utilized in dies and molds is a highly demanding operation. The finite element model was developed to investigate the high speed machining of alloy cast iron which is used in auto panel dies. The modified Johnson-cook constitutive model was used to model the complex dynamic material behavior, a damage evaluation law based on Cockroft and Latham model was used to simulate the ductile fracture of alloy cast iron. The crack initiation and propagation was simulated explicitly using an explicit FEM code. Simulation results showed that the chip morphology transited from continuous to saw-tooth chip with increasing cutting speed, cutting force decreased when increasing the cutting speed, which provide a useful understanding of chip formation process in high speed machining of alloy cast iron.

Finite Element Analysis on Segmented Chip Formation for High Speed Cutting of Ti6Al4V Alloy

2009 ◽  
Vol 407-408 ◽  
pp. 599-603
Author(s):  
Xiang Hua Zhang ◽  
Hong Bing Wu
Keyword(s):  
Finite Element ◽  
Titanium Alloy ◽  
Finite Element Model ◽  
Chip Formation ◽  
High Speed ◽  
Element Model ◽  
High Speed Cutting ◽  
Segmented Chip ◽  
Titanium Alloy Ti6al4v ◽  
The Finite Element Model

To accurately simulate the segmented chip formation of titanium alloy Ti6Al4V in high speed cutting process, the key techniques of the finite element modeling were investigated detailed, which included establishing the finite element model, material constitutive relation, chip separation criteria, material failure criteria. A high speed cutting case of titanium alloy Ti6Al4V were simulated with thermal mechanical analysis and adiabatic analysis respectively. Through the comparison of the two simulated results, it proved the segmented chip is formed because of the adiabatic shear. The results prove the finite element model established is correct.

Investigation on experiment and simulation of the grinding process of cast iron

2020 ◽  
Vol 234 (13) ◽  
pp. 2653-2661
Author(s):  
Lihui Tu ◽  
Jianqiang Li ◽  
Weimin Shi
Keyword(s):  
Residual Stress ◽  
Finite Element ◽  
Cast Iron ◽  
Finite Element Model ◽  
Surface Quality ◽  
Metal Cutting ◽  
Cutting Temperature ◽  
Element Model ◽  
Grinding Force ◽  
Grinding Process

Grinding is used to reduce form error and improve the surface quality of workpiece in metal cutting. To investigate the grinding process of cast iron, a series of grinding tests and simulation of cast iron were carried out. At the same time, the finite element method was used to establish a finite element model to simulate the grinding process of cast iron. In the model, the dynamic effects, thermo-mechanical coupling, Johnson–Cook constitutive model, material damage model, and contact model were taken into account. Then, the grinding process of cast iron was simulated using the established finite element model in the ABAQUS software. Material remove, residual stress, grinding force, and cutting temperature were achieved through the simulation. In addition, the effect of the main grinding parameters (depth of grinding and spindle speed) on residual stress, grinding force, and surface quality in the grinding of cast iron was investigated.

Proposal of a new low-cycle fatigue life model for cast iron with room temperature calibration involving mean stress and high-temperature effects

2019 ◽  
Vol 233 (14) ◽  
pp. 5056-5073 ◽  
Author(s):  
Cristiana Delprete ◽  
Raffaella Sesana
Keyword(s):  
Finite Element ◽  
Cast Iron ◽  
High Temperature ◽  
Finite Element Model ◽  
Life Prediction ◽  
Low Cycle Fatigue ◽  
Element Model ◽  
Mean Stress ◽  
Exhaust Manifold ◽  
Cycle Fatigue

The paper presents and discusses a low-cycle fatigue life prediction energy-based model. The model was applied to a commercial cast iron automotive exhaust manifold. The total expended energy until fracture proposed by the Skelton model was modified by means of two coefficients which take into account of the effects of mean stress and/or mean strain, and the presence of high temperature. The model was calibrated by means of experimental tests developed on Fe–2.4C–4.6Si–0.7Mo–1.2Cr high-temperature-resistant ductile cast iron. The thermostructural transient analysis was developed on a finite element model built to overtake confidentiality industrial restrictions. In addition to the commercial exhaust manifold, the finite element model considers the bolts, the gasket, and a cylinder head simulacrum to consider the corresponding thermal and mechanical boundary conditions. The life assessment performance of the energy-based model with respect the cast iron specimens was compared with the corresponding Basquin–Manson–Coffin and Skelton models. The model prediction fits the experimental data with a good agreement, which is comparable with both the literature models and it shows a better fitting at high temperature. The life estimations computed with respect the exhaust manifold finite element model were compared with different multiaxial literature life models and literature data to evaluate the life prediction capability of the proposed energy-based model.

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