Finite Element Modeling of Cutting Force and Chip Formation During Thermally Assisted Machining of Ti6Al4V Alloy

2013 ◽  
Vol 135 (6) ◽  
Author(s):  
Yao Xi ◽  
Michael Bermingham ◽  
Gui Wang ◽  
Matthew Dargusch
Keyword(s):  
Finite Element ◽  
Finite Element Modeling ◽  
Cutting Force ◽  
Formation Process ◽  
Chip Formation ◽  
Cutting Forces ◽  
Experimental Results ◽  
Strongly Correlated ◽  
Element Modeling ◽  
Simulation Results

The improvement in machinability during thermally assisted turning of the Ti-6Al-4V alloy has been investigated using finite element modeling. A 2D thermally assisted turning model was developed and validated by comparing the simulation results with experimental results. The effect of workpiece temperature on the cutting force and chip formation process was examined. The predicted cutting forces and chip morphologies from the simulation strongly correlated with the experimental results. It was observed from the simulation that the chip forms after the coalescence of two deformed regions in the shear band and that the cyclic cutting forces are strongly related to this chip formation process.

L16 Orthogonal Array-Based Three-Dimensional Finite Element Modeling for Cutting Force and Chip Formation Analysis During Dry Machining of Ti–6Al–4V

2020 ◽  
pp. 1-12
Author(s):  
Raviraj Shetty ◽  
Sanjeev Kumar ◽  
Ravindra Mallagi ◽  
Laxmikanth Keni
Keyword(s):  
Finite Element ◽  
Finite Element Modeling ◽  
Cutting Force ◽  
Chip Formation ◽  
Orthogonal Array ◽  
Three Dimensional ◽  
Cutting Conditions ◽  
Element Modeling ◽  
Dimensional Finite Element ◽  
Three Dimensional Finite Element

The outstanding characteristics of titanium alloy (Ti–6Al–4V) have made this material applicable in aerospace and medical components. However, due to its poor machinability characteristics, researchers are forced to understand the machinability behavior of Ti–6Al–4V. In this paper, [Formula: see text] orthogonal array-based three-dimensional finite element modeling for the cutting force and chip formation analysis during the machining of Ti–6Al–4V using cubic boron nitride tool in dry turning environment has been investigated. The finite element simulation was performed using ANSYS Workbench, version 19.0. Cutting force and chip formation were investigated using the results obtained from [Formula: see text] orthogonal array-based three-dimensional finite element modeling. This research would help to identify the optimum cutting conditions and minimize the cutting force followed by analyzing the types of chips formed during machining under the selected set of cutting conditions.

Experimental and Numerical Machining of AA 5083

2011 ◽  
Vol 189-193 ◽  
pp. 4419-4424
Author(s):  
Behnam Davoodi ◽  
Mohammad Bagher Momeni ◽  
Mohammad Reza Eslami
Keyword(s):  
Finite Element ◽  
Finite Element Modeling ◽  
Chip Formation ◽  
Cutting Forces ◽  
Cutting Speed ◽  
Simulation Software ◽  
Constitutive Law ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Element Modeling

The experimental machining and finite element modeling of 2D turning of AA5083 is presented. The ABAQUS/Explicit machining simulation software is applied for the finite element modeling. The experimental orthogonal machining for were conducted to investigate the effects of various machining parameters on chip morphology, machined surface condition, and resulting cutting forces. The measured cutting forces was compared to finite element modeling results with good agreement. The effects of cutting speed and rack angle of tool cutting factor for productivity in AA5083 machining, depth of cut, on the peak tool temperature are investigated. 2D Finite Element Model (FEM) of chip formation process, set up with an Arbitrary Lagrangian-Eulerian (ALE) formulation, proposed in the software ABAQUS/Explicit .the thermo-viscoplastic behavior of the workpiece material is modeled by the Johnson-Cook (JC) constitutive law. This study explores the use of experimental and finite element modeling to study the cutting force. Results of this research help to guide the design of new cutting tool materials and coatings and the studies of chip formation to further advance the productivity of AA5083 machining.

FEA Modelling of Cutting Force and Chip Formation in Thermally Assisted Machining of Ti6Al4V Alloy

2013 ◽  
Vol 765 ◽  
pp. 343-347 ◽  
Author(s):  
Yao Xi ◽  
Michael Bermingham ◽  
Gui Wang ◽  
Matthew Dargusch
Keyword(s):  
Cutting Force ◽  
Chip Formation ◽  
Cutting Forces ◽  
Finite Element Modelling ◽  
Initial Temperature ◽  
Experimental Results ◽  
Work Piece ◽  
Element Modelling ◽  
Initial Work ◽  
Simulation Results

The improvement of machinability during thermally assisted turning of Ti-6Al-4V alloy was investigated by finite element modelling. A 2D thermally assisted turning model was developed and validated by comparing the simulation results with experimental results. Detailed analyses were carried out on the simulations in terms of the influence of the initial work-piece temperature on cutting forces and chip formation in the TAM process. The predicted cutting forces showed a very good correlation to the experimental results, and both the simulation and experiments have proved that the initial work-piece temperature plays an important role in determining the cutting force, with increasing initial temperature reducing the cutting force.

Investigation of tensile and flexural behavior of biaxial and rib 1 × 1 weft-knitted composite using experimental tests and multi-scale finite element modeling

2019 ◽  
Vol 53 (23) ◽  
pp. 3201-3215 ◽  
Author(s):  
Reza Hessami ◽  
Aliasghar Alamdar Yazdi ◽  
Abbas Mazidi
Keyword(s):  
Finite Element ◽  
Finite Element Modeling ◽  
Experimental Results ◽  
Flexural Behavior ◽  
Bending Tests ◽  
Three Point Bending ◽  
Element Modeling ◽  
Multi Scale ◽  
Scale Modeling ◽  
Composite Samples

In this study, tensile and flexural behavior of biaxial and rib weft-knitted composite is obtained numerically and experimentally. Multi-scale finite element modeling is employed to simulate the tensile and flexural behavior of composite samples. In the finite element modeling, the geometry of a unit cell of each fabric is initially modeled in ABAQUS software, and then periodic boundary conditions were applied to a unit cell. The stiffness matrix for each structure was obtained by a python code via meso scale modeling and used as input data for the macro modeling. To validate the numerical model, two types of weft-knitted fabrics (rib 1 × 1 and biaxial fabrics) are produced by a flat weft knitting machine. Epoxy resin is used to construct composite by the vacuum injection process (VIP). After that, the tensile and three-point bending tests were applied to composite samples. The experimental results showed that tensile strength and tensile modulus of biaxial composites are greater than rib composites, in both wale and course directions. Moreover, in three-point bending test, biaxial composite showed more strength and more stiffness in comparison to rib composite. Finite element results were compared to experimental results in tensile and bending tests. The results showed that good agreement with experimental results in the linear section of tensile and flexural behavior of composites. Consequently, the current multi-scale modeling can be used to predict the stiffness matrix and mechanical behavior of complex composite structures such as knitted composites.

Investigation on Chip Formation during Machining Using Finite Element Modeling

2012 ◽  
Vol 505 ◽  
pp. 31-36 ◽  
Author(s):  
Moaz H. Ali ◽  
Basim A. Khidhir ◽  
Bashir Mohamed ◽  
A.A. Oshkour
Keyword(s):  
Finite Element ◽  
Tool Wear ◽  
Finite Element Modeling ◽  
Chip Formation ◽  
Cutting Tool ◽  
Chip Morphology ◽  
Machining Process ◽  
Element Modeling ◽  
Segmented Chip ◽  
Cutting Speeds

Titanium alloys are desirable materials for aerospace industry because of their excellent combination of high specific strength, lightweight, fracture resistant characteristics, and general corrosion resistance. Therefore, the chip morphology is very important in the study of machinability of metals as well as the study of cutting tool wear. The chips are generally classified into four groups: continuous chips, chips with built-up-edges (BUE), discontinuous chips and serrated chips. . The chip morphology and segmentation play a predominant role in determining machinability and tool wear during the machining process. The mechanics of segmented chip formation during orthogonal cutting of titanium alloy Ti–6Al–4V are studied in detail with the aid of high-speed imaging of the chip formation zone. The finite element model of chip formation of Ti–6Al–4V is suggested as a discontinuous type chip at lower cutting speeds developing into a continuous, but segmented, chip at higher cutting speeds. The prediction by using finite-element modeling method and simulation process in machining while create chips formation can contribute in reducing the cost of manufacturing in terms of prolongs the cutting tool life and machining time saving.

Three-Dimensional Finite Element Analysis on Heavy Cutting for High Strength Steel

2013 ◽  
Vol 274 ◽  
pp. 3-6 ◽  
Author(s):  
Yuan Sheng Zhai ◽  
Xian Li Liu ◽  
Yu Wang
Keyword(s):  
Finite Element ◽  
Finite Element Modeling ◽  
Feed Rate ◽  
Cutting Forces ◽  
High Strength Steel ◽  
Three Dimensional ◽  
High Strength ◽  
Temperature Fields ◽  
Maximum Temperature ◽  
Element Modeling

The finite element modeling and experimental validation of three-dimensional heavy cutting of high strength steel (2.25Cr-1Mo-0.25V) are presented. The commercial software Deform 3D applied for the finite element modeling is studied the effect of feed rate on the principal cutting forces and the temperature fields. The friction between the tool and the chip is assumed to follow a shear model and the local adaptive remeshing technique is used for the formation of chip. The feed rate significantly affects the cutting forces, but slightly influences the maximum temperature of the chip. The simulation results are compared with experimental data and found to be in good agreement.

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