Predicting the Effects of Cutting Parameters and Tool Geometry on Hard Turning Process Using Finite Element Method

2011 ◽  
Vol 133 (4) ◽  
Author(s):  
Xueping Zhang ◽  
Shenfeng Wu ◽  
Heping Wang ◽  
C. Richard Liu
Keyword(s):  
Finite Element ◽  
Feed Rate ◽  
Hard Turning ◽  
Tangential Force ◽  
Cutting Speed ◽  
Chip Morphology ◽  
Rake Angle ◽  
Fe Model ◽  
Turning Process ◽  
Nose Radius

To explore the effects of cutting speed, feed rate and rake angle on chip morphology transition, a thermomechanical coupled orthogonal (2-D) finite element (FE) model is developed, and to determine the effects of tool nose radius and lead angle on hard turning process, an oblique (3-D) FE model is further proposed. Three one-factor simulations are conducted to determine the evolution of chip morphology with feed rate, rake angle, and cutting speed, respectively. The chip morphology evolution from continuous to saw-tooth chip is described by means of the variations of chip dimensional values, saw-tooth chip segmental degree and frequency. The results suggest that chip morphology transits from continuous to saw-tooth chip with increasing feed rate and cutting speed, and changing a tool’s positive rake angle to negative rake angle. There exists a critical cutting speed at which the chip morphology transfers from continuous to saw-tooth chip. The saw-tooth chip segmental frequency decreases as the feed rate and the tool negative rake angle value increases; however, it increases almost linearly with the cutting speed. The larger negative rake angle, the larger feed rate and higher cutting speed dominate saw-tooth chip morphology while positive rake angle, small feed rate and low cutting speed combine to determine continuous chip morphology. The 3-D FE model considers tool nose radii of 0.4 mm and 0.8 mm, respectively, with tool lead angels of 0 deg and 7 deg. The model successfully simulates 3-D saw-tooth chip morphology generated by periodic adiabatic shear and demonstrates the continuous and saw-tooth chip morphology, chip characteristic line and the material flow direction between chip-tool interfaces. The predicted chip morphology, cutting temperature, plastic strain distribution, and cutting forces agree well with the experimental data. The oblique cutting process simulation reveals that a bigger lead angle results in a severer chip deformation, the maximum temperature on the chip-tool interface reaches 1289 deg, close to the measured average temperature of 1100 deg; the predicted average tangential force is 150N, with 7% difference from the experimental data. When the cutting tool nose radius increases to 0.8 mm, the chip’s temperature and strain becomes relatively higher, and average tangential force increases 10N. This paper also discusses reasons for discrepancies between the experimental measured cutting force and that predicted by finite element simulation.

Predicting the Effects of Rake Angle, Cutting Speed and Feed Rate on Chip Morphology in Hard Turning

2010 ◽  
Author(s):  
Shenfeng Wu ◽  
Xueping Zhang ◽  
C. Richard Liu
Keyword(s):  
Feed Rate ◽  
Hard Turning ◽  
Orthogonal Cutting ◽  
Cutting Speed ◽  
Chip Morphology ◽  
Element Model ◽  
Rake Angle ◽  
Fe Model ◽  
Sawtooth Chip ◽  
Continuous Chip

This paper proposes a thermo-mechanical orthogonal cutting finite element model (FEM) to investigate the variation of chip morphology from continuous chip to small and large saw-tooth chip. The corresponding experiments of hard turning AISI 52100 steel are conducted to validate the proposed FE model. Three one-factor simulation experiments are conducted to determine the evolution of chip morphology along feed rate, rake angle and cutting speed respectively. The chip morphology evolution is described by the variations of dimensional values, saw-tooth degree and chip segmental frequency. The research suggests that chip morphology transit from continuous to sawtooth chip with increasing the feed rate and cutting speed, and changing a positive rake angle to a negative rake angle. There exists a critical cutting speed at which the chip morphology transfers from continuous to saw-tooth chips. The saw-tooth chip segmental frequency decreases as the feed rate and negative rake angle value increase, but increases almost linearly with the cutting speed. The larger negative rake angle, the larger feed rate and high cutting speed dominate the sawtooth chip morphology while positive rake angle, small feed rate and low cutting speed determine continuous chip morphology.

Predicting the Effects of Tool Nose Radius and Lead Angle on Hard Turning Process Using 3D Finite Element Method

2010 ◽  
Author(s):  
Xueping Zhang ◽  
Heping Wang ◽  
C. Richard Liu
Keyword(s):  
Experimental Data ◽  
Finite Element Method ◽  
Finite Element ◽  
Hard Turning ◽  
Tangential Force ◽  
Chip Morphology ◽  
Turning Process ◽  
Nose Radius ◽  
Lead Angle ◽  
Tool Nose Radius

Finite element method (FEM) has been qualified as an excellent method to analyze machining processes. Many researchers commonly adopt an orthogonal FE model to simulate hard turning process without considering the effect of tool nose radius and/or lead angle. However, the PCBN cutting tools usually possess a nose radius of 0.4mm to 0.8mm, which equals to the magnitude of cutting depth/feed in hard turning. To explore the effect of tool nose radius and rake angle on hard turning AISI 52100 steel process, an explicit dynamic thermo-mechanical three-dimensional (3D) FEM is developed. The model considers tool nose radius as 0.4mm and 0.8mm, respectively with a tool lead angle of 0° and 7°. The model successfully simulates 3D saw-tooth chip morphology generated by periodic adiabatic shear and demonstrates the continuous and saw-tooth chip morphology, chip characteristic line and the material flow direction between the chip-tool interfaces. The predicted chip morphology, cutting temperature, plastic strain distribution and cutting forces agrees well with the experimental data. The oblique cutting process simulation reveals that larger lead angle enables work material deformation more severely, the maximum temperature on the chip-tool interface reaches 1289°, close to the measured average temperature of 1100°; the predicted average tangential force is 150N, with 7% difference from the experimental data. When the cutting tool nose radius increases to 0.8mm, the chip’s temperature and strain becomes relatively higher, and average tangential force increases 10N. This paper also discusses the disagreement between the predicted and experimental cutting force.

scholarly journals Modeling and Optimizing the Effects of Insert Angles on Hard Turning Performance

2021 ◽  
Vol 2021 ◽  
pp. 1-18
Author(s):  
Pham Minh Duc ◽  
Mai Duc Dai ◽  
Le Hieu Giang
Keyword(s):  
Mathematical Model ◽  
Hard Turning ◽  
Tangential Force ◽  
Cutting Temperature ◽  
Rake Angle ◽  
Cutting Edge ◽  
Turning Process ◽  
Nose Radius ◽  
Positive Effects ◽  
Feed Force

To analyze hard turning performance characteristics, a new mathematical model was developed for the hard turning process, and cutting force (CF), another important response for cutting machining, was also studied in the present work. The analysis of the mathematical model and experimental results revealed that thrust force (Fy) was the largest, followed by tangential force (Fz) and feed force (Fx). The resultant CF was most influenced by inclination angle (IA) with 25.02%, followed by rake angle (RA) (14.26%) and cutting edge angle (CEA) (10.04%). Increasing CEA changed the position of cutting on the tool-nose radius and increased local negative RA and correspondingly local clearance angle (CA). Meanwhile, increasing negative RA and IA resulted in larger local negative RA and CA. Moreover, local RA and local CA were the main geometric factors affecting surface roughness (SR), tool wear (TW), and CF. Increasing local negative RA resulted in higher SR and CF. In contrast, increasing local CA resulted in lower SR, TW, and CF. Under specific conditions, the positive effects of the local CA overcame the negative effects of the local negative RA, leading to a simultaneous decrease in SR and TW. The proposed novel mathematical model can be further applied to calculate local CF, cutting temperature, and TW for each cutting-edge element, to analyze and optimize the hard turning process.

Development of Tooling Cost Model for High Speed Hard Turning

2011 ◽  
Vol 418-420 ◽  
pp. 1482-1485 ◽  
Author(s):  
Erry Yulian Triblas Adesta ◽  
Muataz Al Hazza ◽  
Delvis Agusman ◽  
Agus Geter Edy Sutjipto
Keyword(s):  
Feed Rate ◽  
High Speed ◽  
Hard Turning ◽  
Cost Model ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Rake Angle ◽  
Depth Of Cut ◽  
Predictive Regression ◽  
Aisi 4340

The current work presents the development of cost model for tooling during high speed hard turning of AISI 4340 hardened steel using regression analysis. A set of experimental data using ceramic cutting tools, composed approximately of Al2O3 (70%) and TiC (30%) on AISI 4340 heat treated to a hardness of 60 HRC was obtained in the following design boundary: cutting speeds (175-325 m/min), feed rate (0.075-0.125 m/rev), negative rake angle (0 to -12) and depth of cut of (0.1-0.15) mm. The output data is used to develop a new model in predicting the tooling cost using in terms of cutting speed, feed rate, depth of cut and rake angle. Box Behnken Design was used in developing the model. Predictive regression model was found to be capable of good predictions the tooling cost within the boundary design.

A Study of Relation between Roundness and Cutting Force in CNC Turning Process

2015 ◽  
Vol 799-800 ◽  
pp. 366-371 ◽  
Author(s):  
Deuanphan Chanthana ◽  
Somkiat Tangjitsitcharoen
Keyword(s):  
Cutting Force ◽  
Cutting Forces ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Rake Angle ◽  
Turning Process ◽  
Nose Radius ◽  
Cnc Turning ◽  
Cnc Turning Process ◽  
Tool Nose Radius

The roundness is one of the most important criteria to accept the mechanical parts in the CNC turning process. The relations of the roundness, the cutting conditions and the cutting forces in CNC turning is hence studied in this research. The dynamometer is installed on the turret of the CNC turning machine to measure the in-process cutting force signals. The cutting parameters are investigated to analyze the effects of them on the roundness which are the cutting speed, the feed rate, the depth of cut, the tool nose radius and the rake angle. The experimentally obtained results showed that the better roundness is obtained with an increase in cutting speed, tool nose radius and rake angle. The relation between the cutting parameters and the roundness can be explained by the in-process cutting forces. It is understood that the roundness can be monitored by using the in-process cutting forces.

Investigation of Relation between Straightness and Cutting Force in CNC Turning Process

2015 ◽  
Vol 789-790 ◽  
pp. 812-820 ◽  
Author(s):  
Thararath Shansungnoen ◽  
Somkiat Tangjitsitcharoen
Keyword(s):  
Cutting Force ◽  
Cutting Speed ◽  
Rake Angle ◽  
Cutting Conditions ◽  
Turning Process ◽  
Nose Radius ◽  
Cnc Turning ◽  
Force Ratio ◽  
Cnc Turning Process ◽  
Tool Nose Radius

The objective of this research is to examine the relation between the straightness and the cutting force ratio during the CNC turning process. The cutting force is monitored and obtained by installing the dynamometer on the turret of CNC turning machine. The relation between the cutting force ratio and the straightness is investigated under the various cutting conditions, which are the cutting speed, the feed rate, the depth of cut, the tool nose radius and the rake angle. The experimentally obtained results showed that the straightness can be improved with an increase in cutting speed, tool nose radius and rake angle. The relation between the dynamic cutting force and straightness profile can be proved by checking the frequency of the cutting force in frequency domain with the use of the Fast Fourier Transform (FFT), which is the same as the straightness profile. Hence, the cutting force ratio can be used to predict the straightness during the cutting regardless of the cutting conditions. The cutting force ratio is proposed to predict the straightness during turning process by employing the exponential function for the sake of straightness. The multiple regression analysis has been utilized to calculate the regression coefficients of the in-process prediction of straightness model by using the least square method at 95% confident level. It has been proved by the cutting tests that the in-process straightness can be predicted during the cutting within ±10% measured straightness with the high accuracy of 91.85%.

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.

Achieving Optimal Process Parameters during Hard Turning of AISI 52100 Bearing Steel Using Hybrid GRA-PCA

2019 ◽  
Vol 818 ◽  
pp. 87-91 ◽  
Author(s):  
P. Umamaheswarrao ◽  
D. Ranga Raju ◽  
K.N.S. Suman ◽  
B. Ravi Sankar
Keyword(s):  
Hard Turning ◽  
Cubic Boron Nitride ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Rake Angle ◽  
Bearing Steel ◽  
Depth Of Cut ◽  
Nose Radius ◽  
Aisi 52100 ◽  
Input Parameters

In the present work hard turning of AISI 52100 steel has been performed using Polycrystalline cubic boron nitride (PCBN) tools. The input parameters considered are cutting speed, feed, depth of cut, nose radius and negative rake angle and the measured responses are machining force and workpiece surface temperature. Experiments are planned as per Central Composite Design (CCD) of Response Surface Methodology (RSM). The effect of input parameters and their interactions are discussed with main effects plot. Further, the multi-objective optimization scheme is proposed by adopting Grey Relational Analysis (GRA) coupled with Principle Component Analysis (PCA). Results demonstrated that speed is the most significant factor affecting the responses followed by negative rake angle, feed, depth of cut, and nose radius. The optimum cutting parameters obtained are cutting speed 1000 rpm, feed 0.02 mm/rev, depth of cut 0.5 mm, Nose radius 1 mm and Negative rake angle 5o.

Effect of Cutting Parameters on Surface Texture of Flame Sprayed Coatings

2013 ◽  
Vol 199 ◽  
pp. 396-401
Author(s):  
Robert Starosta
Keyword(s):  
Feed Rate ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Rake Angle ◽  
Depth Of Cut ◽  
Nose Radius ◽  
Clearance Angle ◽  
Approach Angle ◽  
Cutting Inserts

Coatings were turned by two tools: a) ISO 2R 2525K10, geometry and cutting parameters recommended by Messner Eutectic Castolin Company (tool angle β = 90o, approach angle κr = 45o, nose radius rε =0,8 mm, clearance angle α = 6o, rake angle γ = -5o) b) bit tool with CBN WNGA080408S01030A insert mounted in DWLNRL-2525M08 holder (cutting inserts β = 80o, approach angle κr = 95o, nose radius 0,8 mm, clearance angle α = 6o, rake angle γ = -6o). The influence of cutting speed, feed rate, depth of turning on the coating surface roughness was estimated. The following cutting parameters: cutting speed Vc = 45 214 m/min, feed rate f = 0,04 0,196 mm/rev, depth of cut ap = 0,05 0,3 mm. The lowest value of the roughness Ra = 0,5μm of the coatings were obtained by using cutting tools and parameters and bit tool: Vc = 214 m/min, f = 0,06 mm/rev, ap = 0,3 mm.

Finite Element Analysis of Turning Hardened AISI 42100 Bearing Steel With Various Cutting Inserts

2006 ◽  
Author(s):  
Li Qian ◽  
Shuting Lei ◽  
Renji Chen
Keyword(s):  
Finite Element ◽  
Numerical Simulations ◽  
Feed Rate ◽  
High Speed ◽  
Hard Turning ◽  
Bearing Steel ◽  
Depth Of Cut ◽  
Turning Process ◽  
Finish Hard Turning ◽  
Coated Carbide

Finite element simulations of high-speed orthogonal machining were performed to study the finish hard-turning process as a function of cutting speed, feed rate, cutter geometry, and workpiece hardness. The finish hard-turning process is defined as turning materials with hardness higher than 40 HRC (Hardness – Rockwell C), under appropriate high feed rate and low depth of cut conditions. In the simulations, properties representative of AISI 52100 bearing steel hardened to 45, 51 or 58 HRC were assumed for the workpiece. Cubic boron nitride (CBN), titanium aluminum nitride (TiAlN)-coated carbide cutters, and ceramics inserts are widely used as cutting tool material in such high-speed machining of hardened tool steels — due to high hardness, high abrasive wear resistance, and chemical stability at high temperature. The numerical simulations or experiments assumed physical, mechanical, and thermal properties representative of each of the three cutting materials. Cutting forces, tool and workpiece temperature, and residual stresses were determined in the numerical simulations. These resulting trends in forces, temperatures, and residual stress are consistent with experimental results reported in the literature.

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