Simulation of Meso-Scale Machining of AISI1045 Based on Multiphase Model

2016 ◽  
Vol 836-837 ◽  
pp. 374-380
Author(s):  
Teng Yi Shang ◽  
Li Jing Xie ◽  
Xiao Lei Chen ◽  
Yu Qin ◽  
Tie Fu
Keyword(s):  
Cutting Force ◽  
Cutting Process ◽  
Multiphase Model ◽  
Tool Edge Radius ◽  
Edge Radius ◽  
Tool Edge ◽  
Cutting Insert ◽  
Multiphase Models ◽  
Hot Rolled ◽  
Meso Scale

In the meso-scale machining, feed rate, grain size and tool edge radius are in the same order of magnitude, and cutting process is often carried out in the grain interior and grain boundary. In this paper the meso-cutting process of hot-rolled AISI1045 steel is studied and its metallographic microstructure is analyzed for the establishment of multiphase models which incorporate the effect of ferrite and pearlite grains. In order to discover the applicability of multiphase models to the simulation of meso-cutting, three contrast simulation models including multiphase model with rounded-edge cutting insert (model I), multiphase model with sharp edge cutting insert (model II) and equivalent homogeneous material model with rounded-edge cutting insert (model III) are built up for the meso-orthogonal cutting processes of hot-rolled AISI1045. By comparison with the experiments in terms of chip morphology, cutting force and specific cutting force, the most suitable model is identified. Then the stress distiribution is analyzed. And it is found that multiphase model with tool edge radius can give a more accurate prediction of the global variables and reveal more about these important local variables distribution.

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.

Tool Edge Roundness and Stable Build-Up Formation in Finish Machining

1974 ◽  
Vol 96 (4) ◽  
pp. 1258-1267 ◽  
Author(s):  
M. Es. Abdelmoneim ◽  
R. F. Scrutton
Keyword(s):  
Theoretical Analysis ◽  
Cutting Force ◽  
Specific Energy ◽  
Chip Thickness ◽  
Force Measurements ◽  
Undeformed Chip Thickness ◽  
Velocity Discontinuity ◽  
Tool Edge Radius ◽  
Edge Radius ◽  
Tool Edge

The results of cutting force measurements when machining materials which do not form a sizable unstable built-up-edge are compared with the results of a theoretical analysis. This analysis, based partly on the use of circular cylindrical surfaces of velocity discontinuity around the base of the tool, yields specific energy values which are uniquely determined by the value of the undeformed chip thickness in relation to the tool edge radius.

Cutting Force Analysis in Micro Milling of Steel

2013 ◽  
Vol 774-776 ◽  
pp. 1017-1020 ◽  
Author(s):  
Bing Wu ◽  
Huai Zhong Li
Keyword(s):  
Cutting Force ◽  
Experimental Work ◽  
Micro Milling ◽  
Cnc Machine Tool ◽  
Force Analysis ◽  
Cnc Machine ◽  
Tool Edge Radius ◽  
Edge Radius ◽  
Tool Edge ◽  
End Mills

An analysis of cutting force performance in the micro milling on steel has been carried out based on an experimental work using micro flat end mills on a precision CNC machine tool. It has been found that cutting forces occurred at low feed per tooth are relatively high by assessing the averaged peak forces from the experiments. When feed per tooth is relatively close to tool edge radius, the forces were not growing in linearity with the increasing feedrate. This finding indicates the significance of ploughing phenomenon as an effect of tool edge radius in micro milling.

Study on Unique Cutting Phenomena in Micro Endmilling - Mechanism and Possibility to Occur-

2009 ◽  
Vol 76-78 ◽  
pp. 508-513 ◽  
Author(s):  
Mitsuyoshi Nomura ◽  
Takahiro Kawashima ◽  
Takayuki Shibata ◽  
Yoshihiko Murakami ◽  
Masami Masuda ◽  
...  
Keyword(s):  
Tool Wear ◽  
Computer Simulations ◽  
Surface Finish ◽  
Chip Thickness ◽  
Cutting Process ◽  
Uncut Chip Thickness ◽  
Tool Edge Radius ◽  
Edge Radius ◽  
Tool Edge

In micro endmilling, because of small uncut chip thickness comparable to the tool edge radius and low rigidity of tool, the cutting process must frequently transit between rubbing/ploughing and cutting, and it may deteriorate the machining stability, surface finish and tool wear. In this report, such unique cutting phenomena are investigated by modeling a mechanism, computer simulations and experiments. As a result, a possibility of the unique cutting phenomena proposed has been certified.

Extracting Specific Cutting Force Coefficients in Micro Drilling with Tool Edge Radius Effects

2015 ◽  
Vol 799-800 ◽  
pp. 256-260 ◽  
Author(s):  
Ravi Shankar Anand ◽  
Karali Patra
Keyword(s):  
Cutting Force ◽  
Thrust Force ◽  
Chip Thickness ◽  
Cutting Force Coefficients ◽  
Undeformed Chip Thickness ◽  
Tool Edge Radius ◽  
Cutting Coefficients ◽  
Edge Radius ◽  
Tool Edge ◽  
Micro Drilling

This article introduces a methodology for extracting specific cutting force coefficients by performing micro drilling experiments with tool edge radius effect.Tool edge radius mainly affects the effective rake angle that varies according to undeformed chip thickness. Ploughing effect is also considered for undeformed chip thickness lower than the minimum chip thickness. In this work specific normal and frictional cutting coefficients for both ploughing and shearing are determined from mechanistic approach of fitting experimental specific thrust forces of the micro drilling process. The variations of these cutting coefficients with respect to cutting speedand feed are presented. Finally these coefficients have been applied to the mechanistic model to predict thrust force in micro drilling. The predicted thrust force values at different feed show good agreement with the experimental results.

Effects of tool edge radius on chip formation during the micromachining of pure iron

2020 ◽  
Vol 108 (7-8) ◽  
pp. 2121-2130
Author(s):  
Xiaoguang Guo ◽  
Yang Li ◽  
Linquan Cai ◽  
Jiang Guo ◽  
Renke Kang ◽  
...  
Keyword(s):  
Chip Formation ◽  
Pure Iron ◽  
Tool Edge Radius ◽  
Edge Radius ◽  
Tool Edge ◽  
On Chip

On the Steady-State Workpiece Flow Mechanism and Force Prediction Considering Piled-Up Effect and Dead Metal Zone Formation

2020 ◽  
Vol 143 (4) ◽  
Author(s):  
Cheng Hu ◽  
Weiwei Zhang ◽  
Kejia Zhuang ◽  
Jinming Zhou ◽  
Han Ding
Keyword(s):  
Stagnation Point ◽  
Shear Stresses ◽  
Flow Mechanism ◽  
Zone Formation ◽  
Force Prediction ◽  
Tool Edge Radius ◽  
Edge Radius ◽  
Dead Metal Zone ◽  
Tool Edge ◽  
Material Separation

Abstract The manufacturing of miniaturized components is indispensable in modern industries, where the uncut chip thickness (UCT) inevitably falls into a comparable magnitude with the tool edge radius. Under such circumstances, the ploughing phenomenon between workpiece and tool becomes predominant, followed by the notable formation of dead metal zone (DMZ) and piled-up chip. Although extensive models have been developed, the critical material flow status in such microscale is still confusing and controversial. In this study, a novel material separation model is proposed for the demonstration of workpiece flow mechanism around the tool edge radius. First, four critical positions of workpiece material separation are determined, including three points characterizing the DMZ pattern and one inside considered as stagnation point. The normal and shear stresses as well as friction factors along the entire contact region are clarified based on slip-line theory. It is found that the friction coefficient varies symmetrically about the stagnation point inside DMZ and remains constant for the rest. Then, an analytical force prediction model is developed with Johnson–Cook constitutive model, involving calibrated functions of chip-tool contact length and cutting temperature. The assumed tribology condition and morphologies of material separation including DMZ are clearly observed and verified through various finite element (FE) simulations. Finally, comparisons of cutting forces from cutting experiments and predicted results are adopted for the validation of the predictive model.

Finite Element Simulation of Precision Cutting Monocrystalline Silicon

2013 ◽  
Vol 662 ◽  
pp. 99-102 ◽  
Author(s):  
Li Qiu Shi ◽  
Xiao Wen Li ◽  
Feng Yu
Keyword(s):  
High Surface ◽  
Cutting Speed ◽  
Monocrystalline Silicon ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Tool Edge Radius ◽  
Transition Mechanism ◽  
Edge Radius ◽  
Tool Edge ◽  
Optimization Of Cutting Parameters

Monocrystalline silicon is typical of hard brittle materials, a high surface quality can be obtained in ductile-regime cutting. The success of the turning process depends on optimizing the machining parameters such as the tool edge radius, tool rake angles, depth of cut and cutting speed, etc. In this study, based on the ductile–brittle transition mechanism, the optimization of cutting parameters were determined with the commercial, general purpose FEA software Msc.Marc. The result demonstrates that the value of temperature is minimum when the tool rake angle is in the range of -15º～-30º. Smaller tool edge radius was selected while maintaining quality of tool edge radius and tool life. As long as beyond the range of cutting speed 6 ~ 8 mm/s, smaller residual stress can be obtain.

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