Development of a friction model and its application in finite element analysis of minimum quantity lubrication machining of Ti-6Al-4 V

2016 ◽  
Vol 238 ◽  
pp. 181-194 ◽  
Author(s):  
Nilanjan Banerjee ◽  
Abhay Sharma
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Minimum Quantity Lubrication ◽  
Friction Model ◽  
Element Analysis ◽  
Minimum Quantity

3D FEA Modeling of Hard Turning

2002 ◽  
Vol 124 (2) ◽  
pp. 189-199 ◽  
Author(s):  
Y. B. Guo ◽  
C. R. Liu
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Geometric Model ◽  
Friction Model ◽  
Dominant Factor ◽  
Analysis Model ◽  
Element Analysis ◽  
Plastic Properties ◽  
Fea Model ◽  
Model Predictions

A practical explicit 3D finite element analysis model has been developed and implemented to analyze turning hardened AISI 52100 steels using a PCBN cutting tool. The finite element analysis incorporated the thermo-elastic-plastic properties of the work material in machining. An improved friction model has been proposed to characterize tool-chip interaction with the friction coefficient and shear flow stresses determined by force calibration and material tests, respectively. A geometric model has been established to simulate a 3D turning. FEA Model predictions have reasonable accuracy for chip geometry, forces, residual stresses, and cutting temperatures. FEA model sensitivity analysis indicates that the prediction is consistent using a suitable magnitude of material failure strain for chip separation, the simulation gives reasonable results using the experimentally determined material properties, the proposed friction model is valid and the sticking region on the tool-chip interface is a dominant factor of model predictions.

Workpiece Thermal Distortion in Minimum Quantity Lubrication Deep Hole Drilling—Finite Element Modeling and Experimental Validation

2012 ◽  
Vol 134 (1) ◽  
Author(s):  
Bruce L. Tai ◽  
Andrew J. Jessop ◽  
David A. Stephenson ◽  
Albert J. Shih
Keyword(s):  
Heat Flux ◽  
Finite Element ◽  
Heat Carrier ◽  
Three Dimensional ◽  
Minimum Quantity Lubrication ◽  
Hole Drilling ◽  
Bottom Surface ◽  
Thermal Distortion ◽  
Element Analysis ◽  
Minimum Quantity

This paper presents the three dimensional (3-D) finite element analysis (FEA) to predict the workpiece thermal distortion in drilling multiple deep-holes under minimum quantity lubrication (MQL) condition. Heat sources on the drilling hole bottom surface (HBS) and hole wall surface (HWS) are first determined by the inverse heat transfer method. A 3-D heat carrier consisting of shell elements to carry the HWS heat flux and solid elements to carry the HBS heat flux has been developed to conduct the heat to the workpiece during the drilling simulation. A thermal–elastic coupled FEA was applied to calculate the workpiece thermal distortion based on the temperature distribution. The concept of the heat carrier was validated by comparing the temperature calculation with an existing 2-D advection model. The 3-D thermal distortion was validated experimentally on an aluminum workpiece with four deep-holes drilled sequentially. The measured distortion on the reference point was 61 μm, which matches within uncertainty the FEA predicted distortion of 51 μm.

scholarly journals Finite Element Analysis of Sheet Metal FormingTaking Account of Nonlinear Friction Model

2008 ◽  
Vol 49 (573) ◽  
pp. 0995-0999 ◽  
Author(s):  
Koji HASHIMOTO ◽  
Eiji ISOGAI ◽  
Tohru YOSHIDA ◽  
Yukihisa KURIYAMA ◽  
Koichi ITO
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Sheet Metal ◽  
Friction Model ◽  
Nonlinear Friction ◽  
Element Analysis

Application of subloading-overstress friction model to finite element analysis

2014 ◽  
Vol 4 (2) ◽  
Author(s):  
T. Kuwayama ◽  
K. Hashiguchi ◽  
N. Suzuki ◽  
N. Yoshinaga ◽  
S. Ogawa
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Flat Surface ◽  
Surface Friction ◽  
Friction Model ◽  
Sliding Velocity ◽  
Element Analysis ◽  
Contact Behaviour ◽  
Wide Range ◽  
The Finite Element Analysis

Accurate prediction of contact behaviour between machine tools and metals is required for the mechanical design of machinery. In this article, the numerical analysis of the contact behaviour is described by incorporating the subloading-overstress model [6] which is capable of describing the contact behaviour for a wide range of sliding velocity including the increase of coefficient of friction with the increase of sliding velocity. And its validity is verified by the comparison with some test results. First, in order to examine the influence of sliding velocities on the friction properties, the flat-surface friction tests for lubricated interfaces between galvannealed steel sheet and SKD-11 tool steel were performed. As a result, It is observed that the friction smoothly translate to kinetic friction, after exhibiting the peak at the static friction. In addition, it is observed that the higher the sliding velocity, the larger the friction resistance, meaning the positive rate sensitivity. Then the subloading-overstress model is implemented in the finite element analysis program ABAQUS/Standard, and it is used to simulate the flat-surface friction tests. The predictions from the finite element analysis are shown to be in very good agreement with experimental results.

Localization of the Shear Zone in Extrusion Processes by Means of Finite Element Analysis

2009 ◽  
Vol 424 ◽  
pp. 221-226 ◽  
Author(s):  
Matthias Kammler
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Numerical Simulations ◽  
Shear Zone ◽  
Friction Model ◽  
Microstructure Development ◽  
Element Analysis ◽  
Numerical Investigations ◽  
Dead Metal Zone ◽  
The Dead

A characteristic feature of extrusion processes is the formation of a shear zone, which separates the deformation zone and the dead metal zone [1, 2]. The deformations occurring in the shear zone cause inner separation and welding effects, which are of great importance for the material flow and the microstructure development of the extruded profiles. The material in the dead metal zone is not participating directly in the forming process but the shape of this zone influences eminently the forming zone and thus the forming of the extruded profile. Furthermore the extreme shear deformation causes according to the Hall-Petch relationship a significant grain refinement in these regions of extruded profiles [3, 4]. So the knowledge on the effects in the shear zone during extrusion processes is fundamental for subsequent numerical investigations on the microstructure development for example regarding quenching techniques. The aim of this study is to localize the formation of the shear zone during extrusion processes by means of the finite element analysis. On the basis of the assumption that separation and welding effects take place in the shear zone, numerical investigations were carried out to indicate these microscopic effects on the macroscopic scale. The considered process was the extrusion of a solid round profile of the alloy EN AW 6082 at 450°C with a punch velocity of 10.5 mm/s. For the localization of the shear zone mechanical parameters were chosen for a shear criterion, which are taken from numerical simulations. A user subroutine was implemented into the FE-models in order to evaluate the shear criterion for the localization of the shear zone. According to [5, 6] the friction model used for the numerical simulations has a strong influence on the formation of the shear zone. In this study a combined friction model according to [7] was used.

scholarly journals Analytical Model of Two-Directional Cracking Shear-Friction Membrane for Finite Element Analysis of Reinforced Concrete

Materials ◽  
2021 ◽  
Vol 14 (6) ◽  
pp. 1460
Author(s):  
Jeffrey P. Mitchell ◽  
Bum-Yean Cho ◽  
Yoo-Jae Kim
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Shear Strength ◽  
Reinforced Concrete ◽  
Shear Stiffness ◽  
Friction Model ◽  
Element Analysis ◽  
Proposed Model ◽  
Shear Friction ◽  
Load Vector

There are a multitude of existing material models for the finite element analysis of cracked reinforced concrete that provide reduced shear stiffness but do not limit shear strength. In addition, typical models are not based on the actual physical behavior of shear transfer across cracks by shear friction recognized in the ACI 318 Building Code. A shear-friction model was recently proposed that was able to capture the recognized cracked concrete behavior by limiting shear strength as a yielding function in the reinforcement across the crack. However, the proposed model was formulated only for the specific case of one-directional cracking parallel to the applied shear force. This study proposed and generalized an orthogonal-cracking shear-friction model for finite element use. This was necessary for handling the analysis of complex structures and nonproportional loading cases present in real design and testing situations. This generalized model was formulated as a total strain-based model using the approximation that crack strains are equal to total strains, using the proportional load vector, constant vertical load, and modified Newton–Raphson method to improve the model’s overall accuracy.

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