scholarly journals FEM-based comparative study of SQUARE & RHOMBIC INSERT machining performance during turning of AISI-D3 steel

2021 ◽  
Vol 13 (2) ◽  
pp. 143-148
Author(s):  
Anastasios Tzotzis ◽  
◽  
Nikolaos Efkolidis ◽  
Gheorghe Oancea ◽  
Panagiotis Kyratsis ◽  
...  
Keyword(s):  
Finite Element ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
The Finite Element Method ◽  
Machining Simulation ◽  
Machining Performance ◽  
Machining Processes ◽  
Element Analysis ◽  
Friction Forces ◽  
Aisi D3 Steel

Nowadays, employment of the Finite Element Method (FEM) in machining simulation is a common practice to decrease development times and costs, as well as to investigate numerous parameters that affect machining processes. In the present work, the 3D modelling of AISI-D3 hard turning with both square and rhombic inserts is being presented by utilizing a commercially available Finite Element Analysis (FEA) software. Eighteen tests were carried out based on cutting conditions that are recommended for the used tools. Specifically, three levels of cutting speed (75m/min, 110m/min and 140m/min), three levels of feed (0.12mm/rev, 0.16mm/rev and 0.20mm/rev) and depth of cut equal to 0.40mm for all tests, were applied. In order to describe the complex factors that define the model, such as the friction forces, the heat transfer and the pressure due to contact between the tool and the workpiece, a number of acknowledged models were utilized. A comparison of the performance between the two types of tools was made with respect to the developed machining forces and temperature distribution on the workpiece. The findings of the investigation indicate that the specific square tools produce higher values of forces compared to the rhombic ones and approximately the same temperature patterns on the workpiece. The average increase on the produced cutting forces is about 26.4%.

Finite Element Analysis of the Effect of Cutting Speed on the Orthogonal Turning of A359/SiCp MMC

2016 ◽  
Vol 852 ◽  
pp. 304-310
Author(s):  
M.M. Thamizharasan ◽  
Y.J. Nithiya Sandhiya ◽  
K.S. Vijay Sekar ◽  
V.V. Bhanu Prasad
Keyword(s):  
Finite Element ◽  
Matrix Material ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Fe Model ◽  
Element Analysis ◽  
Damage And Fracture ◽  
Orthogonal Turning ◽  
The Matrix ◽  
Cutting Speeds

The application of Metal Matrix Composite (MMC) has been increasing due to its superior strength and wear characteristics but the major challenge is its poor machinability due to the presence of reinforcement in the matrix which is a hindrance during machining. The material behaviour during machining varies with respect to input variables. In this paper the effect of cutting speed during the orthogonal turning of A359/SiCp MMC with TiAlN tool insert is analysed by developing a 2D Finite Element (FE) model in Abaqus FEA code. The FE model is based on plane strain formulation and the element type used is coupled temperature displacement. The matrix material is modeled using Johnson–Cook (J-C) thermal elastic–plastic constitutive equation and chip separation is simulated using Johnson–Cook’s model for progressive damage and fracture with parting line. Particle material is considered to be perfectly elastic until brittle fracture. The tool is considered to be rigid. The FE model analyses the tool interaction with the MMC and its subsequent effects on cutting forces for different cutting speeds and feed rates. The chip formation and stress distribution are also studied. The FE results are validated with the experimental results at cutting speeds ranging from 72 – 188 m/min and feed rates ranging from 0.111 – 0.446 mm/rev at constant depth of cut of 0.5mm.

Micro Machining Simulation Analysis by Finite Element Method

2013 ◽  
Vol 712-715 ◽  
pp. 575-578
Author(s):  
Zhan Min Yin ◽  
Yu Juan Dai
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Simulation Analysis ◽  
Cutting Speed ◽  
Failure Criteria ◽  
Rake Angle ◽  
Depth Of Cut ◽  
Micro Machining ◽  
Machining Processes ◽  
Element Method

Micro machining becomes more and more important with the tendency of miniaturization of components used in various fields from military to civilian applications. The finite element method software Abaqus is used to model the nonlinear thermal force coupled elastic-plastic micro machining processes. Relatively systematic simulation analysis has been introduced based on the model combining the Johnson-Cook failure criteria, element deletion strategy etc. It reveals that the size effect is dominant while the depth of cut reaches the cutting edge radius. The rake angle plays more important roles on the micro machining than that of the cutting speed.

Rapid Finite Element Prediction on Machining Process

2013 ◽  
Author(s):  
Long Meng ◽  
Xueping Zhang ◽  
Anil K. Srivastava
Keyword(s):  
Finite Element ◽  
Programming Model ◽  
Cutting Speed ◽  
Chip Morphology ◽  
Machining Process ◽  
Fe Model ◽  
Machining Processes ◽  
Machined Surface ◽  
Element Analysis ◽  
Python Language

Finite Element Analysis (FEA) is widely used to simulate machining processes. However, in general, it is time consuming, error-prone, and requires repeated efforts to establish a verified successful Finite Element (FE) model. To rapidly investigate the effects of parameters such as tool angle, feed rate, cutting speed, and temperatures generated during the machining process, an efficient approach is proposed in this paper. The technique has been used to achieve rapid FF simulation during turning and milling processes using Python language programming of Abaqus. Sub-model 1 is programmed to simulate the chip formation process in Abaqus/Explicit. Sub-model 2 is programmed to simulate the cooling spring-back process by importing the machined surface into Abaqus/Implicit. The proposed method is capable of simulating the chip morphology, stress, strain and temperature of the machining process with different parameters immediately. The established FE models are automatically solved in batch by programming script. Post-processing is programmed by Abaqus script to easily achieve and evaluate the simulation results. The Programmed FE models are validated in terms of the predicted chip morphology, cutting forces and residual stresses. This method is extraordinarily efficient saving more than 33% simulation time in comparison to existing FEA approach used for machining processes. Moreover, the script is concise, easy to debug, and effectively avoiding interactive mistakes. The rapid programming model provides a novel, efficiency and convenient approach to thoroughly investigate the effects of a large number of parameters on machining processes.

scholarly journals Finite element analysis and modeling of temperature distribution in turning of titanium alloys

10.30544/323 ◽  
2018 ◽  
Vol 24 (1) ◽  
pp. 59-69 ◽  
Author(s):  
Moola Mohan Reddy ◽  
Mohan Kumar ◽  
Kumaraesan Shanmugam
Keyword(s):  
Finite Element ◽  
Temperature Distribution ◽  
Titanium Alloys ◽  
Cutting Force ◽  
Feed Rate ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Surface Model ◽  
Element Analysis

The titanium alloys (Ti-6Al-4V) have been widely used in aerospace, and medical applications and the demand is ever-growing due to its outstanding properties. In this paper, the finite element modeling on machinability of Ti-6Al-4V using cubic boron nitride and polycrystalline diamond tool in dry turning environment was investigated. This research was carried out to generate mathematical models at 95% confidence level for cutting force and temperature distribution regarding cutting speed, feed rate and depth of cut. The Box-Behnken design of experiment was used as Response Surface Model to generate combinations of cutting variables for modeling. Then, finite element simulation was performed using AdvantEdge®. The influence of each cutting parameters on the cutting responses was investigated using Analysis of Variance. The analysis shows that depth of cut is the most influential parameter on resultant cutting force whereas feed rate is the most influential parameter on cutting temperature. Also, the effect of the cutting-edge radius was investigated for both tools. This research would help to maximize the tool life and to improve surface finish.

scholarly journals Finite element simulation and regression modeling of machining attributes on turning AISI 304 stainless steel

2021 ◽  
Vol 8 ◽  
pp. 24
Author(s):  
A. Mathivanan ◽  
M.P. Sudeshkumar ◽  
R. Ramadoss ◽  
Chakaravarthy Ezilarasan ◽  
Ganesamoorthy Raju ◽  
...  
Keyword(s):  
Finite Element ◽  
Stainless Steel ◽  
Cutting Force ◽  
Cutting Speed ◽  
304 Stainless Steel ◽  
Computational Time ◽  
Depth Of Cut ◽  
Aisi 304 Stainless Steel ◽  
Machining Processes ◽  
Aisi 304

To-date, the usage of finite element analysis (FEA) in the area of machining operations has demonstrated to be efficient to investigate the machining processes. The simulated results have been used by tool makers and researchers to optimize the process parameters. As a 3D simulation normally would require more computational time, 2D simulations have been popular choices. In the present article, a Finite Element Model (FEM) using DEFORM 3D is presented, which was used to predict the cutting force, temperature at the insert edge, effective stress during turning of AISI 304 stainless steel. The simulated results were compared with the experimental results. The shear friction factor of 0.6 was found to be best, with strong agreement between the simulated and experimental values. As the cutting speed increased from 125 m/min to 200 m/min, a maximum value of 750 MPa stress as well as a temperature generation of 650 °C at the insert edge have been observed at rather higher feed rate and perhaps a mid level of depth of cut. Furthermore, the Response Surface Methodology (RSM) model is developed to predict the cutting force and temperature at the insert edge.

Finite Element Analysis for Deformation of Toolholder/Spindle Interface System at High Rotation Speed

2004 ◽  
Vol 471-472 ◽  
pp. 649-653 ◽  
Author(s):  
D.L. Wang ◽  
T.H. Li ◽  
D.C. Kang
Keyword(s):  
Finite Element ◽  
Rotation Speed ◽  
Cutting Tools ◽  
Cutting Speed ◽  
The Finite Element Method ◽  
Element Analysis ◽  
High Cutting Speed ◽  
Interface System ◽  
Machining System ◽  
High Rotation Speed

With a significant progress achieved both in new kind of cutting tools and in machine tool design at high cutting speed, one of the weakest parts in the machining system is the toolholder/spindle interface system. In this paper the displacement of the 7/24 tapered tool interface and the HSK tool interface at high rotation speed is analyzed by means of the finite element method. The effects of the centrifugal force on the characteristics of the joints are investigated.

Towards Predicting Relative Belt Edge Endurance With the Finite Element Method

1990 ◽  
Vol 18 (4) ◽  
pp. 216-235 ◽  
Author(s):  
J. De Eskinazi ◽  
K. Ishihara ◽  
H. Volk ◽  
T. C. Warholic
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Three Dimensional ◽  
The Finite Element Method ◽  
Shear Deformations ◽  
Element Analysis ◽  
Vertical Loading ◽  
Predicted Values ◽  
Element Method

Abstract The paper describes the intention of the authors to determine whether it is possible to predict relative belt edge endurance for radial passenger car tires using the finite element method. Three groups of tires with different belt edge configurations were tested on a fleet test in an attempt to validate predictions from the finite element results. A two-dimensional, axisymmetric finite element analysis was first used to determine if the results from such an analysis, with emphasis on the shear deformations between the belts, could be used to predict a relative ranking for belt edge endurance. It is shown that such an analysis can lead to erroneous conclusions. A three-dimensional analysis in which tires are modeled under free rotation and static vertical loading was performed next. This approach resulted in an improvement in the quality of the correlations. The differences in the predicted values of various stress analysis parameters for the three belt edge configurations are studied and their implication on predicting belt edge endurance is discussed.

Tire Cornering Simulation Using an Explicit Finite Element Analysis Code

1998 ◽  
Vol 26 (2) ◽  
pp. 109-119 ◽  
Author(s):  
M. Koishi ◽  
K. Kabe ◽  
M. Shiratori
Keyword(s):  
Finite Element Method ◽  
Finite Element Analysis ◽  
Finite Element ◽  
Test System ◽  
Experimental Results ◽  
The Finite Element Method ◽  
Element Analysis ◽  
Explicit Finite Element ◽  
Explicit Finite Element Analysis ◽  
Element Method

Abstract The finite element method has been used widely in tire engineering. Most tire simulations using the finite element method are static analyses, because tires are very complex nonlinear structures. Recently, transient phenomena have been studied with explicit finite element analysis codes. In this paper, the authors demonstrate the feasibility of tire cornering simulation using an explicit finite element code, PAM-SHOCK. First, we propose the cornering simulation using the explicit finite element analysis code. To demonstrate the efficiency of the proposed simulation, computed cornering forces for a 175SR14 tire are compared with experimental results from an MTS Flat-Trac Tire Test System. The computed cornering forces agree well with experimental results. After that, parametric studies are conducted by using the proposed simulation.

Analysis of Hydroelectric Unit’s Upper Bracket Based on Test and FEM

2014 ◽  
Vol 721 ◽  
pp. 131-134
Author(s):  
Mi Mi Xia ◽  
Yong Gang Li
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Element Model ◽  
The Finite Element Method ◽  
Ansys Software ◽  
Element Analysis ◽  
Hydroelectric Unit ◽  
The Finite Element Analysis ◽  
Strain Rosette ◽  
The Finite Element Model

To research the load upper bracket of Francis hydroelectric unit, then established the finite-element model, and analyzed the structure stress of 7 operating condition points with the ANSYS software. By the strain rosette test, acquired the data of stress-strain in the area of stress concentration of the upper bracket. The inaccuracy was considered below 5% by analyzing the contradistinction between the finite-element analysis and the test, and match the engineering precision and the test was reliable. The finite-element method could be used to judge the stress of the upper bracket, and it could provide reference for the Structural optimization and improvement too.

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