Effect Mechanism of Nitrogen Gas on Chip Formation in High Speed Cutting of Ti6Al4V Alloy Based on FEM Simulation

2009 ◽  
Vol 626-627 ◽  
pp. 177-182 ◽  
Author(s):  
Wei Zhao ◽  
Ning He ◽  
Liang Li
Keyword(s):  
Finite Element ◽  
Chip Formation ◽  
High Speed ◽  
Ti6al4v Alloy ◽  
Cutting Process ◽  
Nitrogen Gas ◽  
High Speed Cutting ◽  
Finite Element Software ◽  
On Chip ◽  
Cutting Speeds

Titanium alloys are known for their strong chemical reactivity with surrounding gas due to their high chemical affinity, especially in dry machining. This paper describes a study of chip formation characteristics under nitrogen gas media when machining Ti6Al4V alloy with WC-Co cemented carbide cutting tools at high cutting speeds. Based on the experimental study, a finite element model of two-dimensional orthogonal cutting process for Ti6Al4V alloy at different cutting conditions was developed using a commercial finite element software Deform-2D. Saw-tooth chips with adiabatic shear bands were produced in both experiments and simulations. And the enhanced cooling and anti-frictional effects of nitrogen gas upon the high speed cutting process of Ti6Al4V alloy were analyzed. Results of this investigation indicate that the anti-frictional performance of nitrogen gas has a significant effect on chip formation when machining Ti6Al4V alloy at high cutting speeds. Compared to air, Nitrogen gas is more suitable in improving the contact conditions at chip-tool interfaces and in increasing the shear band frequency of chip formation during high speed cutting of Ti6Al4V alloy.

Study on Residual Stress in High-Speed Cutting NAK80 Mold-Steel

2012 ◽  
Vol 217-219 ◽  
pp. 458-462
Author(s):  
Jian Xin Pan ◽  
Zhi Xiong Zhou
Keyword(s):  
Residual Stress ◽  
Finite Element ◽  
High Speed ◽  
Orthogonal Cutting ◽  
Tool Geometry ◽  
Stress Distributions ◽  
High Speed Cutting ◽  
Finite Element Software ◽  
Cutting Model ◽  
Cutting Speeds

An orthogonal cutting model was presented，and the cutting process was simulated by a finite element software based on the thermal-elastic-plastic FEM theory and updated Lagrange method.We obtained the distributions of residual stresses in machined layer of NAK80 mold-steel.The effects of cutting speeds，cutting depths and tool geometry on residual stress distributions were investigated. Comparing to experimental results，the conclusions are more accurate.

Finite Element Analysis of High Speed Cutting Tool

2012 ◽  
Vol 268-270 ◽  
pp. 496-499 ◽  
Author(s):  
Wei Fan ◽  
Xin Liu
Keyword(s):  
Finite Element ◽  
High Speed ◽  
Metal Cutting ◽  
Cutting Tool ◽  
Cutting Process ◽  
Machining Process ◽  
Tool Geometry ◽  
High Speed Machining ◽  
High Speed Cutting ◽  
Finite Element Software

The cutting principle of high speed machining is analyzed, and the key technology of building high speed cutting finite element simulation model is systemic explained. By simplifying high speed cutting process, using the fastest solution of nonlinear finite element software ADINA which is development in recent years to establish the three dimensional finite element model of high speed metal cutting, and to predict the cutting force of different cutting tool geometry parameter combination of high speed cutting process, the high speed cutting processing cutting tool analysis and processing parameter optimization analysis method are put forwarded, so as to provide a new tool for the research of high speed machining process and provide basis for the cutting tool choice during high-speed nc cutting process.

Study on Finite Element Simulation of the Influence of Cutting Speed on Chip Formation of SiCpAl Composites in High Speed Milling

2014 ◽  
Vol 800-801 ◽  
pp. 290-295
Author(s):  
Chuang Liu ◽  
Shu Tao Huang ◽  
Ke Ru Jiao ◽  
Li Fu Xu
Keyword(s):  
Finite Element ◽  
Chip Formation ◽  
High Speed ◽  
Volume Fraction ◽  
Cutting Speed ◽  
High Volume ◽  
High Volume Fraction ◽  
High Speed Milling ◽  
Finite Element Software ◽  
High Efficient

Application prospect of the high volume fraction SiCp/Al composites becomes increasingly widespread, the study of cutting mechanism is important for achieving its high efficient and precision machining. In this paper, a three-dimensional beveled simulation model of high volume fraction SiCp/Al composites on high-speed milling is established by finite element software ABAQUS, the constitutive on model material, the tool-chip contact and the chip separation model is elected reasonably.The paper analyzes the effect of cutting speed on the chip formation and the stress distribution of the material. The results shows that: with the increasing of cutting speed, the chip is easily broken, cutting speed have little impact on the maximum stress of the material.

Finite Element Simulation on High Speed Cutting of Hardened 45 Steel Based on ABAQUS

2013 ◽  
Vol 579-580 ◽  
pp. 202-207
Author(s):  
Guo He Li ◽  
Hou Jun Qi ◽  
Bing Yan
Keyword(s):  
Finite Element ◽  
Cutting Force ◽  
Finite Element Simulation ◽  
High Speed ◽  
Cutting Temperature ◽  
Cutting Parameters ◽  
Cutting Process ◽  
High Speed Cutting ◽  
Geometry Model ◽  
Element Simulation

For the high speed cutting process of hardened 45 steel (45HRC), a finite element simulation of cutting deformation, cutting force and cutting temperature is finished with the large general finite element software ABAQUS. Through the building of geometry model, material model and heat conduction model, also the determination of boundary conditions, separation rule and friction condition, a thermal mechanical coupling finite element model of high speed cutting for hardened 45 steel is built. The serrated chip, cutting force and cutting temperature can be predicted. The comparison of experiment and simulation shows the validity of the model. The influence of cutting parameters on cutting process is investigated by the simulation under different cutting depthes and rake angles. The results show that as the increase of rake angle, the segment degree, cutting force and cutting temperature decrease. But the segment degree, also the cutting force and cutting temperature increase with the increase of cutting depth. This study is useful for the selection of cutting parameters of hardened steel.

Finite Element Investigation of the Influence of Thermophysical Parameters on Segmented Chip Formation during High Speed Cutting

2011 ◽  
Vol 130-134 ◽  
pp. 2817-2821
Author(s):  
You Xi Lin ◽  
Cong Ming Yan
Keyword(s):  
Thermal Conductivity ◽  
Finite Element ◽  
Specific Heat ◽  
Chip Formation ◽  
High Speed ◽  
Element Model ◽  
Serrated Chip ◽  
High Speed Cutting ◽  
Thermophysical Parameters ◽  
Serrated Chip Formation

A 2D fully thermal mechanical coupled finite element model is applied to study the influence of material parameters on serrate chip formation during high speed cutting process. The serrated chip formation during high speed machining was predicted. Of interests are the effects of thermal conductivity, specific heat and density. Results showed significant influence of these thermophysical parameters on the serrated chip phenomena, especially in the case of the density. Increasing thermal conductivity specific heat and density lead to a decreasing degree of segmentation. The influence of the thermal conductivity on the cutting force and the specific heat on maximum temperatures in the shear band is also discussed.

Finite Element Analysis of Cutting Forces in High Speed Machining

2006 ◽  
Vol 532-533 ◽  
pp. 753-756 ◽  
Author(s):  
Jun Zhao ◽  
Xing Ai ◽  
Zuo Li Li
Keyword(s):  
Finite Element ◽  
Cutting Force ◽  
Cutting Forces ◽  
High Speed ◽  
Fem Simulation ◽  
Chip Thickness ◽  
Cutting Conditions ◽  
Cutting Process ◽  
Undeformed Chip Thickness ◽  
High Speed Cutting

The Finite Element Method (FEM) has proven to be an effective technique to investigate cutting process so as to improve cutting tool design and select optimum cutting conditions. The present work focuses on the FEM simulation of cutting forces in high speed cutting by using an orthogonal cutting model with variant undeformed chip thickness under plane-strain condition to mimic intermittent cutting process such as milling. High speed cutting of 45%C steel using uncoated carbide tools are simulated as the application of the proposed model. The updated Lagrangian formulation is adopted in the dynamic FEM simulation in which the normalized Cockroft and Latham damage criterion is used as the ductile fracture criterion. The simulation results of cutting force components under different cutting conditions show that both the thrust cutting force and the tangential cutting force increase with the increase in undeformed chip thickness or feed rate, whereas decrease with the increase in cutting speed. Some important aspects of modeling the high speed cutting are discussed as well to expect the future work in FEM simulation.

scholarly journals Study on Chip Formation in Ultra High Speed Cutting

1970 ◽  
Vol 36 (429) ◽  
pp. 663-668
Author(s):  
Akira YAMAMOTO ◽  
Shimesu NAKAMURA ◽  
Motosada KANDA
Keyword(s):  
Chip Formation ◽  
High Speed ◽  
High Speed Cutting ◽  
Ultra High Speed ◽  
On Chip

CHIP FORMATION ANALYSIS FOR HIGH SPEED CUTTING

2003 ◽  
Vol 02 (02) ◽  
pp. 247-254 ◽  
Author(s):  
YAN LUO
Keyword(s):  
Tool Wear ◽  
Chip Formation ◽  
High Speed ◽  
Production Management ◽  
New Technologies ◽  
Manufacturing Cost ◽  
High Speed Cutting ◽  
On Chip ◽  
Machining Strategies ◽  
Chip Geometry

Enterprise has to reduce time and cost of product development to face global competition. New technologies and machining strategies have been widely adopted in manufacturing enterprise such as high-speed cutting (HSC). Tool wear prediction will be useful for tool management and thus, reducing the manufacturing cost of HSC. This related project is developed at the Institute of Production Management, Technology and Machine Tools (PTW), TU Darmstadt. The aim of the project is to find a solution to predict tool wear by calculation for HSC. This paper focuses on chip formation analysis. Chip geometry will be generated and calculated to estimate tool wear. The paper presents an algorithm to visualize chip geometry for ball end tool and discusses further the parameters features of chip section.

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