scholarly journals Experimental measurement of the cutting forces and wear of the drill in processing X17CrNi16-2 martensitic stainless steel

2021 ◽  
Vol 12 (1) ◽  
pp. 269-287
Author(s):  
Adrian Sorin Rosca ◽  
Nicolae Craciunoiu ◽  
Ionut Daniel Geonea ◽  
Leonard Ciurezu Gherghe
Keyword(s):  
Thrust Force ◽  
Strain Gauges ◽  
Element Analysis ◽  
Axial Thrust ◽  
Iron And Steel ◽  
Industrial Manufacturing ◽  
Analogue Signals ◽  
Acquisition Device ◽  
Thrust And Torque ◽  
Good Agreement

Abstract. For the optimum setup of an industrial manufacturing process, it can be important to know the drilling forces and moments. In many cases, theoretical estimates are not accurate enough, especially when dealing with new materials, and experimental measurements are mandatory. This paper presents the design of a dynamometer comprising a one-spoked wheel elastic component to measure the drilling thrust force and the drilling moment. A finite element analysis was made, using Ansys software, to find the most favorable position for the strain gauges. One set of strain gauges was bonded to spokes to determine the torque, and a second set was bonded to the other two spokes to quantify the axial thrust force. After dynamometer manufacturing, a calibration operation is achieved, and tests are performed by measuring the drilling forces, thrust, and torque on American Iron and Steel Institute (AISI) 1020 steel. The analogue signals from the gauges were recorded using a computer with a data acquisition device. Tool wear is studied, and the results are presented in the paper. A good agreement between results from the literature and computations demonstrates the efficiency and accuracy of this measuring instrument.

Drilling Characteristics of an E-Glass Fabric-Reinforced Polypropylene Composite and an Aluminum Alloy: A Comparative Study

2007 ◽  
Vol 129 (6) ◽  
pp. 1080-1087 ◽  
Author(s):  
C. Dandekar ◽  
E. Orady ◽  
P. K. Mallick
Keyword(s):  
Aluminum Alloy ◽  
Temperature Rise ◽  
Feed Rate ◽  
Thrust Force ◽  
Cutting Speed ◽  
Glass Fabric ◽  
Maximum Temperature ◽  
Polypropylene Composite ◽  
Axial Thrust ◽  
Thrust And Torque

This paper presents an experimental study on the drilling characteristics of an E-glass fabric-reinforced polypropylene composite and aluminum alloy 6061-T6. Both materials have many similar structural applications, especially in the automotive industry. The drilling characteristics considered were axial thrust force, torque, temperature increase during drilling, and chip morphology. Both axial thrust force and torque were significantly higher for the aluminum alloy but were independent of the cutting speed for both materials. However, both increased linearly with increasing feed rate for the composite, but nonlinearly for the aluminum alloy. The Shaw-Oxford equation for predicting axial thrust and torque worked well with the aluminum alloy but did not fit the composite’s axial thrust and torque characteristics. Both materials exhibited temperature rise at locations close to the drilled hole. The temperature rise decreased with increasing feed rate as well as increasing cutting speed; however, the maximum temperature rise in the composite was significantly lower than that in the aluminum alloy. There was also a significant difference in the morphology of chips of these two materials.

Drilling Thrust and Torque Prediction of Viscoplastic Materials

2006 ◽  
Author(s):  
Hossein Vaghefpour ◽  
Ali Nayebi
Keyword(s):  
Shear Zone ◽  
Cutting Forces ◽  
Material Flow ◽  
Thrust Force ◽  
Orthogonal Cutting ◽  
Thermomechanical Properties ◽  
Twist Drill ◽  
Proposed Model ◽  
Thrust And Torque ◽  
Good Agreement

A model for drilling of viscoplastic materials is presented. An analytical model is developed for predicting thrust force and torque in the drilling with a twist drill. The thermomechanical properties are accounted for describing the material flow in the primary shear zone and at the element-chip interface. A temperature friction law is introduced. The approach is based on the representing the cutting forces along the cutting lips as a series of oblique elements. Similarly, cutting in the chisel region is treated as orthogonal cutting with different speeds depending on the radial location. The section forces obtained by the model are combined to determine the overall thrust force and drilling torque. The results of the proposed model are compared with experimental results and a good agreement is obtained.

Computer Modeling of a Tire under Cornering Loads

1989 ◽  
Vol 17 (2) ◽  
pp. 86-99 ◽  
Author(s):  
I. Gardner ◽  
M. Theves
Keyword(s):  
Finite Element Analysis ◽  
Geometric Approach ◽  
Lateral Force ◽  
Slip Angle ◽  
Element Analysis ◽  
Pressure Distributions ◽  
Slip Effects ◽  
Improved Accuracy ◽  
Nonlinear Geometric ◽  
Good Agreement

Abstract During a cornering maneuver by a vehicle, high forces are exerted on the tire's footprint and in the contact zone between the tire and the rim. To optimize the design of these components, a method is presented whereby the forces at the tire-rim interface and between the tire and roadway may be predicted using finite element analysis. The cornering tire is modeled quasi-statically using a nonlinear geometric approach, with a lateral force and a slip angle applied to the spindle of the wheel to simulate the cornering loads. These values were obtained experimentally from a force and moment machine. This procedure avoids the need for a costly dynamic analysis. Good agreement was obtained with experimental results for self-aligning torque, giving confidence in the results obtained in the tire footprint and at the rim. The model allows prediction of the geometry and of the pressure distributions in the footprint, since friction and slip effects in this area were considered. The model lends itself to further refinement for improved accuracy and additional applications.

Thermo-Mechanical Modeling and Analysis of Equal Channel Angular Pressing

2005 ◽  
Vol 23 ◽  
pp. 263-266 ◽  
Author(s):  
Qing Xiang Pei ◽  
B.H. Hu ◽  
C. Lu
Keyword(s):  
Equal Channel Angular Pressing ◽  
Temperature Rise ◽  
Flow Behavior ◽  
Material Model ◽  
Workpiece Material ◽  
Element Analysis ◽  
Modeling And Analysis ◽  
Die Geometry ◽  
Angular Pressing ◽  
Good Agreement

Thermo-mechanical finite element analysis was carried out to study the deformation behavior and temperature distribution during equal channel angular pressing (ECAP). The material model used is the Johnson-Cook constitution model that can consider the multiplication effect of strain, strain rate, and temperature on the flow stress. The effects of pressing speed, pressing temperature, workpiece material and die geometry on the temperature rise and flow behavior during ECAP process were investigated. The simulated temperature rise due to deformation heating was compared with published experimental results and a good agreement was obtained. Among the various die geometries studied, the two-turn die with 0° round corner generates the highest and most uniform plastic strain in the workpiece.

Experimental and theoretical study of sandwich composites with Z-pins under quasi-static compression loading

2021 ◽  
pp. 136943322110073
Author(s):  
Erdem Selver ◽  
Gaye Kaya ◽  
Hussein Dalfi
Keyword(s):  
Vinyl Ester ◽  
Failure Modes ◽  
Critical Role ◽  
Sandwich Composites ◽  
Test Results ◽  
Compressive Properties ◽  
Element Analysis ◽  
Static Compression ◽  
Quasi Static Compression ◽  
Good Agreement

This study aims to enhance the compressive properties of sandwich composites containing extruded polystyrene (XPS) foam core and glass or carbon face materials by using carbon/vinyl ester and glass/vinyl ester composite Z-pins. The composite pins were inserted into foam cores at two different densities (15 and 30 mm). Compression test results showed that compressive strength, modulus and loads of the sandwich composites significantly increased after using composite Z-pins. Sandwich composites with 15 mm pin densities exhibited higher compressive properties than that of 30 mm pin densities. The pin type played a critical role whilst carbon pin reinforced sandwich composites had higher compressive properties compared to glass pin reinforced sandwich composites. Finite element analysis (FE) using Abaqus software has been established in this study to verify the experimental results. Experimental and numerical results based on the capabilities of the sandwich composites to capture the mechanical behaviour and the damage failure modes were conducted and showed a good agreement between them.

Experimental, numerical and parametric studies on stress concentration factors of T-joints under tension

2021 ◽  
pp. 136943322110499
Author(s):  
Feleb Matti ◽  
Fidelis Mashiri
Keyword(s):  
Finite Element ◽  
Stress Concentration ◽  
Numerical Study ◽  
Hot Spot ◽  
Joint Models ◽  
Element Analysis ◽  
T Joints ◽  
Concentration Factors ◽  
Stress Concentration Factors ◽  
Good Agreement

This paper investigates the behaviour of square hollow section (SHS) T-joints under static axial tension for the determination of stress concentration factors (SCFs) at the hot spot locations. Five empty and corresponding concrete-filled SHS-SHS T-joint connections were tested experimentally and numerically. The experimental investigation was carried out by attaching strain gauges onto the SHS-SHS T-joint specimens. The numerical study was then conducted by developing three-dimensional finite element (FE) T-joint models using ABAQUS finite element analysis software for capturing the distribution of the SCFs at the hot spot locations. The results showed that there is a good agreement between the experimental and numerical SCFs. A series of formulae for the prediction of SCF in concrete-filled SHS T-joints under tension were proposed, and good agreement was achieved between the maximum SCFs in SHS T-joints calculated from FE T-joint models and those from the predicted formulae.

Burst Pressure of Pressurized Cylinders With Hillside Nozzle

2009 ◽  
Vol 131 (4) ◽  
Author(s):  
H. F. Wang ◽  
Z. F. Sang ◽  
L. P. Xue ◽  
G. E. O. Widera
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Experimental Models ◽  
Burst Pressure ◽  
Element Analysis ◽  
Test Models ◽  
Scale Test ◽  
Failure Location ◽  
Dimensional Instability ◽  
Good Agreement

The burst pressure of cylinders with hillside nozzle is determined using both experimental and finite element analysis (FEA) approaches. Three full-scale test models with different angles of the hillside nozzle were designed and fabricated specifically for a hydrostatic test in which the cylinders were pressurized with water. 3D static nonlinear finite element simulations of the experimental models were performed to obtain the burst pressures. The burst pressure is defined as the internal pressure for which the structure approaches dimensional instability, i.e., unbounded strain for a small increment in pressure. Good agreement between the predicted and measured burst pressures shows that elastic-plastic finite element analysis is a viable option to estimate the burst pressure of the cylinders with hillside nozzles. The preliminary results also suggest that the failure location is near the longitudinal plane of the cylinder-nozzle intersection and that the burst pressure increases slightly with an increment in the angle of the hillside nozzle.

Finite Element Analysis of Metal Flow of Finishing Groove in Hot Continuous Rolling Bar

2012 ◽  
Vol 510 ◽  
pp. 667-672
Author(s):  
Jia Lin Zhou ◽  
Chen Gang Pan ◽  
Xiao Yong Zhang
Keyword(s):  
Strain Distribution ◽  
Metal Flow ◽  
Dimensional Accuracy ◽  
Stress And Strain ◽  
Fe Model ◽  
Element Analysis ◽  
Iron And Steel ◽  
Expansion Angle ◽  
The Stability ◽  
Stress And Strain Distribution

This article established 3D FE model of dual-radius arc finishing groove and tangent expansion angle finishing groove using ANSYS / LS-DYNA software for Wuhan Iron and Steel plant Ф16 hot continuous bar, and analyzed metal flow pattern, stress and strain distribution of two types finishing grooves. The results show that surface stress and strain distribution of dual-radius arc finishing groove have better uniform than them of tangent expansion angle finishing groove, and dual-radius arc finishing groove ensures the stability of the rolled piece in finishing groove, improve the dimensional accuracy and surface quality of rolled finishing product.

Initial Investigation Into Helical Milling of Laminated Stacks of Electrical Steel

2012 ◽  
Author(s):  
Howard Liles ◽  
J. Rhett Mayor
Keyword(s):  
Electrical Steel ◽  
Thrust Force ◽  
Initial Study ◽  
Helical Milling ◽  
Burr Formation ◽  
Spring Back ◽  
Plunge Milling ◽  
Axial Thrust ◽  
Electrical Steels ◽  
Thrust Forces

This paper serves to report the findings of an initial study on the holing of laminated stacks of electrical steels. Three different holing methods were considered: plunge milling, helical milling (orbit milling), and drilling. Stack delamination, axial thrust force, and burr formation were measured at various feed rates for each process and utilized as comparison metrics. Results from the initial experimental investigation indicate that drilling produces significant burr and plunge milling, whilst reducing burr formation compared to drilling, led to delamination of the stack. Helical milling minimized thrust forces, avoided delamination and minimized burr formation. An interesting spring back effect was also observed during the cutting of the laminated stacks. It is concluded that helical milling is a viable and effective processing method for making holes in laminated stack of hard electrical steels.

scholarly journals Numerical simulation and experimental comparison of flaw evolution on a bearing raceway: Case of thrust ball bearing

2018 ◽  
Vol 5 (4) ◽  
pp. 427-434 ◽  
Author(s):  
M.Y. Toumi ◽  
S. Murer ◽  
F. Bogard ◽  
F. Bolaers
Keyword(s):  
Structural Damage ◽  
Ball Bearing ◽  
Rolling Contact ◽  
Experimental Comparison ◽  
Ball Bearings ◽  
Damage State ◽  
Element Analysis ◽  
Rolling Surface ◽  
Experimental Apparatus ◽  
Good Agreement

Abstract Bearings are essential elements in the design of rotating machines. In an industrial context, bearing failure can have costly consequences. This paper presents a study of the rolling contact fatigue damage applied to thrust ball bearings. It consists in building a dynamic three-dimensional numerical model of the cyclic shift of a ball on an indented rolling surface, using finite element analysis (FEA). Assessment of the evolution in size of a surface spall as a function of loading cycles is also performed using FEM coupled with fatigue laws. Results are in good agreement with laboratory tests carried out under the same conditions using a fatigue test cell dedicated to ball bearings. This study may improve knowledge about estimating the lifetime of rolling components after onset of a spall using FEA and accounting for structural damage state. Highlights The experimental apparatus and damaged thrust ball bearing are described. We model a portion of the thrust ball bearing featuring a spherical indent. Numerical results in terms of stress field are compared to analytical results from the literature. A fatigue software is used to assess the evolution of spalling size. Good agreement is obtained between experimental test campaigns at different loads and FEA results.

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