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.

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.

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.

scholarly journals Studies of thin-walled parts deformation by gripping force during turning process on an example of bearing ring

2018 ◽  
Vol 244 ◽  
pp. 02010
Author(s):  
Adam Patalas ◽  
Michał Regus ◽  
Katarzyna Peta
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Turning Process ◽  
Turning Operation ◽  
Geometrical Accuracy ◽  
Bearing Ring ◽  
Thin Walled ◽  
Gripping Force ◽  
Element Method

In this paper thin-walled part deformation during finishing turning process caused by gripping force of hydraulic lathe chuck was investigated. Bearing ring was taken as an example of thin-walled part undergo finishing turning operation. Finite Element Method (FEM) was used to define the deformation of examined part. The aim of presented research was to compare the deformation of bearing ring caused by gripping force of hydraulic 3-jaw chuck and 6-jaw chuck for different values of total gripping force. The data obtained from conducted simulations allowed to evaluate the influence of gripping force on machining part deformation which is directly related with its geometrical accuracy.

Modification of Pre-Cracked Charpy Specimens for Surveillance Specimen Programs

2009 ◽  
Author(s):  
Boris Margolin ◽  
Vladimir Nikolaev ◽  
Valentin Fomenko ◽  
Lev Ryadkov
Keyword(s):  
Experimental Data ◽  
Finite Element Method ◽  
Fracture Toughness ◽  
Finite Element ◽  
Brittle Fracture ◽  
Stress And Strain ◽  
Test Results ◽  
Deep Side ◽  
Strain Fields ◽  
Calculation Analysis

Application of pre-cracked Charpy specimens with various depth of side-grooves is considered for fracture toughness prediction. Recommendations for prediction of temperature dependence of fracture toughness are given when using small-sized specimens with deep side-grooves. Test results of about 500 specimens, cut from materials with various degrees of embrittlement are presented. On the basis of 3D calculations by finite element method the procedure used in standard ASTM E 1921 for calculation of Ke and J, is developed for bending specimens with deep side-grooves. An attempt is undertaken to explain the obtained experimental data from the standpoints of the available criteria of brittle fracture based on calculation analysis of stress and strain fields (SSF) of SE(B)-10 specimens with various depths of side-grooves.

Finite Element Simulation of RC Beam Strengthened with FRP

2012 ◽  
Vol 446-449 ◽  
pp. 3229-3232
Author(s):  
Chao Jiang Fu
Keyword(s):  
Experimental Data ◽  
Finite Element Method ◽  
Finite Element ◽  
Numerical Analysis ◽  
Finite Element Simulation ◽  
Fiber Reinforced Polymer ◽  
Rc Beam ◽  
The Finite Element Method ◽  
Reinforced Polymer ◽  
Element Simulation

The finite element modeling is established for reinforced concrete(RC) beam reinforced with fiber reinforced polymer (FRP) using the serial/parallel mixing theory. The mixture algorithm of serial/parallel rule is studied based on the finite element method. The results obtained from the finite element simulation are compared with the experimental data. The comparisons are made for load-deflection curves at mid-span. The numerical analysis results agree well with the experimental results. Numerical results indicate that the proposed procedure is validity.

Finite Element Calculation of Sintering Deformation Using Limited Experimental Data

2008 ◽  
Vol 606 ◽  
pp. 103-118 ◽  
Author(s):  
Jing Zhe Pan ◽  
Ruo Yu Huang
Keyword(s):  
Experimental Data ◽  
Finite Element Method ◽  
Finite Element Analysis ◽  
Finite Element ◽  
Ceramic Powder ◽  
Material Model ◽  
Element Analysis ◽  
Ceramic Components ◽  
On Line ◽  
Element Method

Predicting the sintering deformation of ceramic powder compacts is very important to manufactures of ceramic components. In theory the finite element method can be used to calculate the sintering deformation. In practice the method has not been used very often by the industry for a very simple reason – it is more expensive to obtain the material data required in a finite element analysis than it is to develop a product through trial and error. A finite element analysis of sintering deformation requires the shear and bulk viscosities of the powder compact. The viscosities are strong functions of temperature, density and grain-size, all of which change dramatically in the sintering process. There are two ways to establish the dependence of the viscosities on the microstructure: (a) by using a material model and (b) by fitting the experimental data. The materials models differ from each other widely and it can be difficult to know which one to use. On the other hand, obtaining fitting functions is very time consuming. To overcome this difficulty, Pan and his co-workers developed a reduced finite element method (Kiani et. al. J. Eur. Ceram. Soc., 2007, 27, 2377-2383; Huang and Pan, J. Eur. Ceram. Soc., available on line, 2008) which does not require the viscosities; rather the densification data (density as function of time) is used to predict sintering deformation. This paper provides an overview of the reduced method and a series of case studies.

Stresses in Thick Pressure Vessel Heads

1990 ◽  
Vol 112 (1) ◽  
pp. 108-114
Author(s):  
A. V. Singh ◽  
V. Kumar
Keyword(s):  
Experimental Data ◽  
Finite Element Method ◽  
Finite Element ◽  
Pressure Vessel ◽  
The Finite Element Method ◽  
Solid Of Revolution ◽  
Wide Range ◽  
Radial Thrust ◽  
Thrust Load ◽  
Spherical Pressure

The finite element method is used to study stresses in two types of spherical pressure vessel heads having very wide range of applications in industries. The first problem involves a nozzle to sphere intersection reinforced by a pad and subjected to radial thrust load. The second problem deals with a pressurized thick hemispherical drumhead with a circular manhole. These structures are modeled using eight-node axisymmetric solid of revolution finite elements. Numerical values of circumferential and meridional stresses from the present analysis show excellent agreement with experimental data from the literature.

An Evaluation of the Mechanical Behaviour of Imperfect Aluminium Tubes

2005 ◽  
Author(s):  
Pieter F. J. Henning ◽  
Leon Pretorius ◽  
Rudolph F. Laubscher
Keyword(s):  
Experimental Data ◽  
Finite Element Method ◽  
Finite Element ◽  
Mechanical Behaviour ◽  
3D Model ◽  
Reaction Force ◽  
Circular Tubes ◽  
Geometric Changes ◽  
Method Model ◽  
Spiral Grooves

In this research the effect of geometric changes introduced on Al 6063-T6 circular tubes in the form of horizontal and spiral grooves, (Fig. 2 and Fig. 3) is assessed. The horizontal and spiral grooves were cut into the tube to a depth of half the wall thickness of the tubes, while the pitch was varied for both the horizontal and spiral grooves, and the cut width was kept constant. These tubes were axially compressed, and load vs. displacement and Energy vs. displacement graphs were generated from the captured experimental data for the tubes. A Finite Element Method model is presented for each of the experimentally tested tubes. 2D models for the uncut and horizontally grooved tubes and a 3D model for the spiral cut tube were generated and analyzed. Reaction force vs. displacement and energy vs. displacement graphs are presented for the different analyses. A comparison is made between the numerically and experimentally determined gradients of the energy vs. displacement graphs for each of the tubes analyzed. This forms the basis for an energy absorber design with application in the transport industry currently under consideration.

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.

Finite element modeling of hard turning process via a micro-textured tool

2015 ◽  
Vol 78 (9-12) ◽  
pp. 1393-1405 ◽  
Author(s):  
Dong Min Kim ◽  
Vivek Bajpai ◽  
Bo Hyun Kim ◽  
Hyung Wook Park
Keyword(s):  
Finite Element ◽  
Finite Element Modeling ◽  
Hard Turning ◽  
Turning Process ◽  
Element Modeling
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