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.

Finite Element Modeling of the Workpiece Thermal Distortion in MQL Deep-Hole Drilling

2011 ◽  
Author(s):  
Bruce L. Tai ◽  
Steven B. White ◽  
David A. Stephenson ◽  
Albert J. Shih
Keyword(s):  
Heat Flux ◽  
Finite Element ◽  
Finite Element Modeling ◽  
Heat Carrier ◽  
Hole Drilling ◽  
Thermal Distortion ◽  
Deep Hole ◽  
Deep Hole Drilling ◽  
Element Modeling ◽  
Carrier Model

This paper develops a three dimensional (3-D) finite element modeling (FEM) to predict the workpiece thermal distortion in minimum quantity lubrication (MQL) deep-hole drilling. Drilling-induced heat fluxes on the drilled hole bottom surface (HBS) and hole wall surface (HWS) are first determined by the inverse heat transfer method. The proposed 3-D heat carrier model consisting of shell elements to carry the HWS heat flux and solid elements to carry the HBS heat flux conducts the heat to the workpiece to mimic drilling process. A coupled thermal-elastic analysis is used to calculate the workpiece thermal distortion at each time step based on the temperature distribution. The heat carrier model is validated by comparing the temperature profiles at selected points with those from an existing 2-D axisymmetric advection model. The capability for modeling distortion in the case of drilling multiple deep-holes is also demonstrated.

Study on Finite Element Analysis Models of Slant Rig Working Course

2012 ◽  
Vol 569 ◽  
pp. 363-367
Author(s):  
Fa Guang Jiang ◽  
Zheng Liang ◽  
Li Wen Zhang
Keyword(s):  
Finite Element ◽  
Working Conditions ◽  
Complex Structure ◽  
Three Dimensional ◽  
Influential Factor ◽  
Present Condition ◽  
Hole Drilling ◽  
Element Analysis ◽  
Drilling Rig ◽  
Three Dimensional Finite Element

Slant-hole drilling rig, which can be used to drill inclined well from the ground, is used widely. During designing and research, it is very important to meet working reliability and requirement under various loads and working conditions. As for the complex structure of slant-hole drilling rig, we cannot get the real analytical solutions at present condition. Therefore, the paper establish the three-dimensional finite element models which are about the lifting process and working conditions of slant-hole drilling rig, study the applied loads of each working condition and analyze the stress-strain regulation of slant-hole drilling rig and its influential factor. Based on the analytical results of deformation and stress, an improvement scheme for the slant-hole drilling rig’s structure can is put forward.

Workpiece Temperature During Deep-Hole Drilling of Cast Iron Using High Air Pressure Minimum Quantity Lubrication

2013 ◽  
Vol 135 (3) ◽  
Author(s):  
Bruce L. Tai ◽  
David A. Stephenson ◽  
Albert J. Shih
Keyword(s):  
Heat Flux ◽  
Cast Iron ◽  
Heat Generation ◽  
Minimum Quantity Lubrication ◽  
Air Pressure ◽  
Hole Drilling ◽  
Deep Hole ◽  
Deep Hole Drilling ◽  
Workpiece Temperature ◽  
Minimum Quantity

This research investigates heat generation and workpiece temperature during deep-hole drilling of cast iron under a high air pressure minimum quantity lubrication (MQL). The hole wall surface (HWS) heat flux, due to drill margin friction and high temperature chips, is of particular interest in deep-hole drilling since it potentially increases the workpiece thermal distortion. This study advances a prior drilling model to quantify the effect of higher air pressure on MQL drilling of cast iron, which is currently performed via flood cooling. Experiments and numerical analysis for drilling holes 200 mm in depth on nodular cast iron work material with a 10 mm diameter drill were conducted. Results showed that the low drill penetration rate can cause intermittent chip clogging, resulting in tremendous heat; however this phenomenon could be eliminated through high air pressure or high feed and speed. Conversely, if the drilling process is stable without chip clogging and accumulation, added high air pressure is found to have no effect on heat generation. The heat flux though the HWS contributes over 66% of the total workpiece temperature rise when intermittent chip clogging occurs, and around 20% to 30% under stable drilling conditions regardless of the air pressure. This paper demonstrated the significance of HWS heat flux and the potential of high air pressure used in conjunction with MQL technology.

scholarly journals Finite Element Analysis and Experimental Evaluation of Residual Stress of Zr-4 alloys Processed through Swaging

Metals ◽  
2020 ◽  
Vol 10 (10) ◽  
pp. 1281 ◽  
Author(s):  
Gaurav Singh ◽  
Bijit Kalita ◽  
K. I. Vishnu Narayanan ◽  
Umesh Kumar Arora ◽  
Manas M. Mahapatra ◽  
...  
Keyword(s):  
Residual Stress ◽  
Finite Element ◽  
Nuclear Power ◽  
Zirconium Alloy ◽  
True Strain ◽  
Three Dimensional ◽  
Element Model ◽  
Hole Drilling ◽  
Element Analysis ◽  
Hole Drilling Method

Zirconium alloy has been extensively used as a cladding material in nuclear power reactors due to its low neutron absorption cross section, excellent mechanical properties, and corrosion resistance. The influence of the swaging parameter, feed rate (0.7, 1.25, 2 m/min) on residual stress induced in Zr-4 alloy is investigated in the present work. A three-dimensional finite element model was implemented in the Deform 3D software to simulate the rotary swaging (RS) process over a circular rod of Zr-4 alloy. The simulation results based on the 3D framework provide a detailed insight of residual stress, true stress versus true strain and force applied over the rod during the multiple pass swaging process; the results are compared with experimental results. The experimental hole drilling method is used to determine the residual stresses on swaged zirconium alloy at different feed rates (0.7, 1.25, and 2 m/min). A similar trend of residual stress between experimental and numerical results from the surface to the center on the swaged rod samples is observed. The same magnitude of residual stress at the surface of the swaged Zr-4 rod is also observed. It is found to be compressive at the surface and tensile in the center of the samples, as observed in the present work.

scholarly journals Finite Element Analysis of Fiber Cement Corrugated Roofing Sheet under Bending

2020 ◽  
Vol 5 (8) ◽  
pp. 955-957
Author(s):  
Vincent Chinedum Okafor ◽  
Peter E. Ogunoh ◽  
Ogochukwu C. Okechukwu
Keyword(s):  
Finite Element ◽  
Three Dimensional ◽  
Element Model ◽  
Bottom Surface ◽  
Element Analysis ◽  
Stress Contour ◽  
Load Carrying ◽  
Dimensional Finite Element ◽  
Tensional Stress ◽  
Three Dimensional Finite Element

The study presents a numerical model for evaluation of the stresses in corrugated sheets under bending. The numerical analysis was performed from a three dimensional finite element model. From the analysis, the most intense tensional stress occurs in the trough and bottom surface of the corrugated sheet. While the most intense value of compressive stress occur in the crest and top surface of the sheet. Based on the principal stress contour diagram, the researcher also observed that the maximum uniformly distributed load carrying capacity of the fiber-cement corrugated sheet under bending, considering the linear material properties is 710N.

Effects of occlusal scheme on All-on-Four abutments, screws and prostheses: A three-dimensional finite element study

2020 ◽  
Author(s):  
Nurullah Türker ◽  
Hümeyra Tercanlı Alkış ◽  
Steven J Sadowsky ◽  
Ulviye Şebnem Büyükkaplan
Keyword(s):  
Finite Element ◽  
Three Dimensional ◽  
Good Prognosis ◽  
Von Mises Stress ◽  
Element Analysis ◽  
Group Function ◽  
Occlusal Contact ◽  
Maximum Deformation ◽  
Contact Points ◽  
Von Mises

An ideal occlusal scheme plays an important role in a good prognosis of All-on-Four applications, as it does for other implant therapies, due to the potential impact of occlusal loads on implant prosthetic components. The aim of the present three-dimensional (3D) finite element analysis (FEA) study was to investigate the stresses on abutments, screws and prostheses that are generated by occlusal loads via different occlusal schemes in the All-on-Four concept. Three-dimensional models of the maxilla, mandible, implants, implant substructures and prostheses were designed according to the All-on-Four concept. Forces were applied from the occlusal contact points formed in maximum intercuspation and eccentric movements in canine guidance occlusion (CGO), group function occlusion (GFO) and lingualized occlusion (LO). The von Mises stress values for abutment and screws and deformation values for prostheses were obtained and results were evaluated comparatively. It was observed that the stresses on screws and abutments were more evenly distributed in GFO. Maximum deformation values for prosthesis were observed in the CFO model for lateral movement both in the maxilla and mandible. Within the limits of the present study, GFO may be suggested to reduce stresses on screws, abutments and prostheses in the All-on-Four concept.

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.

Torsional Analysis of a Steel Cord-Rubber Tire Belt Structure

1996 ◽  
Vol 24 (4) ◽  
pp. 339-348 ◽  
Author(s):  
R. M. V. Pidaparti
Keyword(s):  
Finite Element ◽  
Finite Element Model ◽  
Composite Structures ◽  
Three Dimensional ◽  
Element Model ◽  
Torsional Stiffness ◽  
Element Analysis ◽  
Rubber Belt ◽  
Steel Cord ◽  
Torsional Analysis

Abstract A three-dimensional (3D) beam finite element model was developed to investigate the torsional stiffness of a twisted steel-reinforced cord-rubber belt structure. The present 3D beam element takes into account the coupled extension, bending, and twisting deformations characteristic of the complex behavior of cord-rubber composite structures. The extension-twisting coupling due to the twisted nature of the cords was also considered in the finite element model. The results of torsional stiffness obtained from the finite element analysis for twisted cords and the two-ply steel cord-rubber belt structure are compared to the experimental data and other alternate solutions available in the literature. The effects of cord orientation, anisotropy, and rubber core surrounding the twisted cords on the torsional stiffness properties are presented and discussed.

Finite Element Modeling for Steel Cord Analysis in Radial Tires

2013 ◽  
Vol 41 (1) ◽  
pp. 60-79 ◽  
Author(s):  
Wei Yintao ◽  
Luo Yiwen ◽  
Miao Yiming ◽  
Chai Delong ◽  
Feng Xijin
Keyword(s):  
Finite Element ◽  
High Efficiency ◽  
Force Measurement ◽  
Three Dimensional ◽  
Local Stress ◽  
Tension Force ◽  
Center Line ◽  
Element Analysis ◽  
Design Variables ◽  
Steel Cord

ABSTRACT: This article focuses on steel cord deformation and force investigation within heavy-duty radial tires. Typical bending deformation and tension force distributions of steel reinforcement within a truck bus radial (TBR) tire have been obtained, and they provide useful input for the local scale modeling of the steel cord. The three-dimensional carpet plots of the cord force distribution within a TBR tire are presented. The carcass-bending curvature is derived from the deformation of the carcass center line. A high-efficiency modeling approach for layered multistrand cord structures has been developed that uses cord design variables such as lay angle, lay length, and radius of the strand center line as input. Several types of steel cord have been modeled using the developed method as an example. The pure tension for two cords and the combined tension bending under various loading conditions relevant to tire deformation have been simulated by a finite element analysis (FEA). Good agreement has been found between experimental and FEA-determined tension force-displacement curves, and the characteristic structural and plastic deformation phases have been revealed by the FE simulation. Furthermore, some interesting local stress and deformation patterns under combined tension and bending are found that have not been previously reported. In addition, an experimental cord force measurement approach is included in this article.

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