Temperature Field Correlation With Surface Integrity in Hard Milling

2011 ◽  
Author(s):  
H. M. Singh ◽  
Y. B. Guo
Keyword(s):  
Finite Element ◽  
Surface Integrity ◽  
Orthogonal Cutting ◽  
Cutting Speed ◽  
Milling Process ◽  
Temperature Deformation ◽  
Hard Milling ◽  
Workpiece Interaction ◽  
Cutting Model ◽  
Insight Into

Experimental and FEA study is conducted to get an insight into critical mechanisms of temperature, deformation, stress generation and variations with cutting speed and tool wear in hard milling AISI H13 steel (50±1 HRC). The critical issues like energy consumption during milling and the resulting surface integrity of the machined component depend on the tool and workpiece interaction. An insight into tool and workpiece interaction is needed in order to design a better milling process for required surface integrity. 2D finite element simulation of orthogonal cutting model is performed to investigate the variations of temperatures and residual stresses at different cutting speeds and tool wears. Hard milling experiments are conducted to correlate with the simulation results. The fact that in hard milling, the temperature does not penetrate deep into the workpiece and there is no clear evidence of heat affected zone such as white layer is demonstrated. With the finite element simulations and experiments, the capability of hard milling process to achieve better surface integrity on the machined surface is explored.

Residual Stresses Modelling of End Milling Process Using Numerical and Experimental Methods

2020 ◽  
Vol 978 ◽  
pp. 106-113
Author(s):  
Marimuthu K. Prakash ◽  
Kumar C.S. Chethan ◽  
Prasada H.P. Thirtha
Keyword(s):  
Finite Element ◽  
Residual Stresses ◽  
End Milling ◽  
Orthogonal Cutting ◽  
Milling Process ◽  
Parent Material ◽  
Machining Processes ◽  
Element Analysis ◽  
1045 Steel ◽  
Cutting Model

Machining has been one of the most sort of process for realizing different products. It has significant role in the value additions process. Machining is one of the production process where material is removed from the parent material to realize the final part or component. Among machining, the well known machining processes are turning, milling, shaping, grinding and non-conventional machining processes like electric discharge machining, ultrasonic machining, chemical machining etc. The fundamental of all these processes being material removal in the form of chips using a tool either in contact or not in contact. In the present work, milling is being taken for study Finite element analysis is being used as a tool to understand the different phenomenon that underlies the machining processes. Of late, the machining induced residual stresses is of great interest to the researchers since the residual stresses have an impact on the functional performances. The present work is to model the milling process to predict the forces and residual stresses using finite element method. Unlike many researchers, the authors have attempted to develop oblique cutting model rather than an orthogonal cutting model. The present work was carried out on AISI 1045 steel.

The Finite Element Simulation of Milling Based on Orthogonal Cutting Model

2012 ◽  
Vol 499 ◽  
pp. 208-212
Author(s):  
Ai Hua Gao ◽  
Fu Rong Wang ◽  
Jian Xin Zhang
Keyword(s):  
Finite Element ◽  
Service Life ◽  
Finite Element Simulation ◽  
Metal Cutting ◽  
Orthogonal Cutting ◽  
Milling Process ◽  
Machining Process ◽  
Element Simulation ◽  
Basic Parameters ◽  
Cutting Model

The paper make the service life of relieving formed milling cutter as the optimization objective, proceed the simulation study on the mechanical degree of cutter, cutting data. The concrete method is that the orthogonal milling model is established to simulate the simulation milling process, some basic parameters which are obtained in the machining process are analyzed and discussed. The results indicate that the finite element simulation of the metal cutting processing can analyze quantitatively some physical properties, such as the cutting force, stress, strain and so on, the traditional way of qualitative analysis is changed. The state of machining is in favour of grasping in the theory, the theory and technology are provided to establish the proper processing technology strategy.

Finite Element and Experimental Analysis of Edge Defects Formation during Orthogonal Cutting of SiCp/Al Composites

2012 ◽  
Vol 500 ◽  
pp. 146-151 ◽  
Author(s):  
Ning Hou ◽  
Li Zhou ◽  
Shu Tao Huang ◽  
Li Fu Xu
Keyword(s):  
Finite Element ◽  
Chip Formation ◽  
Defect Formation ◽  
Orthogonal Cutting ◽  
Cutting Speed ◽  
Rake Angle ◽  
Critical Transition ◽  
Cutting Depth ◽  
Edge Defect ◽  
Edge Defects

In this paper, a finite element method was used to dynamically simulate the process of the edge defects formation during orthogonal cutting SiCp/Al composites. The influence of the cutting speed, cutting depth and rake angle of the PCD insert on the size of the edge defects have been investigated by using scanning electron. According to the simulated results, it can be provided that the cutting layer material has an effect on transfer stress and hinder the chip formation in the critical transition stage, and the critical transition point and distance are defined in this stage. The negative shear phenomenon is found when the chip transit to the edge defects in the flexure deformation stage, so the process of the chip formation is the basis of the edge defects formation. In addition, the relationship between the nucleation and propagation direction of the crack and the variation of the edge defect shape on the workpiece was investigated by theory, and it found that the negative shear angle formation is the primary cause of the edge defect formation. A mixed mode crack is found in the crack propagation stage. The sizes of edge defects were measured by the experiment and simulation, and the edge defect size decrease with the increasing of tool rake angle, while increase with increasing cutting depth and cutting speed.

FEM Simulation of the Residual Stress in the Machined Surface Layer for High-Speed Machining

2006 ◽  
Vol 315-316 ◽  
pp. 140-144 ◽  
Author(s):  
Su Yu Wang ◽  
Xing Ai ◽  
Jun Zhao ◽  
Z.J. Lv
Keyword(s):  
Residual Stress ◽  
Finite Element ◽  
Surface Layer ◽  
Residual Stresses ◽  
High Speed ◽  
Metal Cutting ◽  
Orthogonal Cutting ◽  
High Speed Machining ◽  
Machined Surface ◽  
Cutting Model

An orthogonal cutting model was presented to simulate high-speed machining (HSM) process based on metal cutting theory and finite element method (FEM). The residual stresses in the machined surface layer were obtained with various cutting speeds using finite element simulation. The variations of residual stresses in the cutting direction and beneath the workpiece surface were studied. It is shown that the thermal load produced at higher cutting speed is the primary factor affecting the residual stress in the machined surface layer.

scholarly journals Finite Element Analysis and Statistical Optimization of End-Burr in Turning AA2024

Metals ◽  
2019 ◽  
Vol 9 (3) ◽  
pp. 276 ◽  
Author(s):  
Muhammad Asad ◽  
Hassan Ijaz ◽  
Waqas Saleem ◽  
Abdullah Mahfouz ◽  
Zeshan Ahmad ◽  
...  
Keyword(s):  
Finite Element ◽  
Orthogonal Cutting ◽  
Research Work ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Shear Zones ◽  
Statistical Analyses ◽  
Burr Formation ◽  
Pivot Point ◽  
Exit Edge

This contribution presents three-dimensional turning operation simulations exploiting the capabilities of finite element (FE) based software Abaqus/Explicit. Coupled temperature-displacement simulations for orthogonal cutting on an aerospace grade aluminum alloy AA2024-T351 with the conceived numerical model have been performed. Numerically computed results of cutting forces have been substantiated with the experimental data. Research work aims to contribute in comprehension of the end-burr formation process in orthogonal cutting. Multi-physical phenomena like crack propagation, evolution of shear zones (positive and negative), pivot-point appearance, thermal softening, etc., effecting burr formation for varying cutting parameters have been highlighted. Additionally, quantitative predictions of end burr lengths with foot type chip formation on the exit edge of the machined workpiece for various cutting parameters including cutting speed, feed rate, and tool rake angles have been made. Onwards, to investigate the influence of each cutting parameter on burr lengths and to find optimum values of cutting parameters statistical analyses using Taguchi’s design of experiment (DOE) technique and response surface methodology (RSM) have been performed. Investigations show that feed has a major impact, while cutting speed has the least impact in burr formation. Furthermore, it has been found that the early appearance of the pivot-point on the exit edge of the workpiece surface results in larger end-burr lengths. Results of statistical analyses have been successfully correlated with experimental findings in published literature.

Finite Element Modeling of Orthogonal Cutting of Pyrolytic Carbon

2011 ◽  
Author(s):  
Gautam Salhotra ◽  
Vivek Bajpai ◽  
Ramesh K. Singh
Keyword(s):  
Finite Element ◽  
Transverse Isotropy ◽  
Orthogonal Cutting ◽  
Chip Morphology ◽  
Pyrolytic Carbon ◽  
Cutting Conditions ◽  
Prediction Errors ◽  
Machining Parameters ◽  
Machined Surface ◽  
Cutting Model

Engineered features on pyrolytic carbon (PyC) have been demonstrated as an approach to improve the flow hemodynamics of the cardiovascular implants. In addition, it also finds application in thermonuclear components. These micro/meso scale engineered features are required to be machined onto the PyC leaflet. However, being a layered anisotropic material and brittle in nature, its machining characteristics differ from plastically deformable isotropic materials. Consequently, this study is aimed at creating a finite element model to understand the mechanics of material removal in the plane of transverse isotropy (horizontally stacked laminae) of PyC. A layered model approach has been used to capture the interlaminar shearing and brittle fracture during machining. A cohesive element layer has been used between the chip layer and the machined surface layer. The chip layer and workpiece are connected through a cohesive layer. The model predicts cutting forces and the chip length for different cutting conditions. The orthogonal cutting model has been validated against experimental data for different cutting conditions for cutting and thrust forces. Parametric studies have also been performed to understand effect of machining parameters on machining responses. This model also predicts chip lengths which have also been compared with the actual chip morphology obtained from microgrooving experiments. The prediction errors for cutting force and chip length are within 20% and 33%, respectively.

An Approach on Fuzzy and Regression Modeling for Hard Milling Process

2015 ◽  
Vol 813-814 ◽  
pp. 498-504 ◽  
Author(s):  
A. Tamilarasan ◽  
D. Rajamani ◽  
A. Renugambal
Keyword(s):  
Manufacturing Systems ◽  
Metal Removal ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Milling Process ◽  
Regression Modeling ◽  
Average Error ◽  
Depth Of Cut ◽  
Hard Milling ◽  
Radial Depth

This paper proposes the prediction of cutting temperature, tool wear and metal removal rate using fuzzy and regression modeling techniques for the hard milling process. The feed per tooth, radial depth of cut, axial depth of cut and cutting speed were used as process state variables.The experiements were conducted using RSM based central composite rotatable design methodology. Regression and fuzzy modeling were used to evaluate the input – output relationship in the process. It is interesting to observe that the R2 and average error values for each response are very consistent with small variations were obtained.Also, the confirmation results show that very less relative error varitions. Thus, the developed fuzzy models directly integrated in manufacturing systems to reduce the more computational complexity in the process planning activities.

Finite Element Modeling of Chip Formation in the Domain of Negative Rake Angle Cutting

2003 ◽  
Vol 125 (3) ◽  
pp. 324-332 ◽  
Author(s):  
Y. Ohbuchi ◽  
T. Obikawa
Keyword(s):  
Finite Element ◽  
Finite Element Modeling ◽  
Orthogonal Cutting ◽  
Cutting Speed ◽  
Chip Thickness ◽  
Rake Angle ◽  
Undeformed Chip Thickness ◽  
Element Modeling ◽  
Single Grain ◽  
Serrated Chips

A thermo-elastic-plastic finite element modeling of orthogonal cutting with a large negative rake angle has been developed to understand the mechanism and thermal aspects of grinding. A stagnant chip material ahead of the tool tip, which is always observed with large negative rake angles, is assumed to act like a stable built-up edge. Serrated chips, one of typical shapes of chips observed in single grain grinding experiment, form when analyzing the machining of 0.93%C carbon steel SK-5 with a rake angle of minus forty five or minus sixty degrees. There appear high and low temperature zones alternately according to severe and mild shear in the primary shear zone respectively. The shapes of chips depend strongly on the cutting speed and undeformed chip thickness; as the cutting speed or the undeformed chip thickness decreases, chip shape changes from a serrated type to a bulging one to a wavy or flow type. Therefore, there exists the critical cutting speed over which a chip can form and flow along a rake face for a given large negative rake angle and undeformed chip thickness.

Computer Simulation for the Orthogonal Milling Process of Asphalt Concrete

2010 ◽  
Vol 139-141 ◽  
pp. 1014-1017
Author(s):  
Li Qun Zhou ◽  
Yu Ping Li ◽  
Hong Liu ◽  
Guo Xing
Keyword(s):  
Asphalt Concrete ◽  
Shear Fracture ◽  
Orthogonal Cutting ◽  
Cutting Speed ◽  
Adaptive Mesh ◽  
Surface Friction ◽  
Element Model ◽  
Failure Criteria ◽  
Milling Process ◽  
Contact Pair

So as to design the pavement planer, it is necessary to study the milling performance of asphalt concrete. In this work, a coupled thermo-mechanical plane-strain large deformation orthogonal cutting finite element model is presented to simulate the asphalt concrete milling process and predict the stress and temperature field on the cutter. Chip separation is considered by applying shear fracture failure criteria and element deletion and adaptive mesh technique. Two contact pairs are defined. Contact pair 1 defines the milling path, and contact pair 2 defines to prevent the formed chip enter into the workpiece. The Johnson-Cook’s constitutive relation is adopted for the asphalt material. The cutter surface friction and heat conduction are considered. The computation indicates that the maximal cutting force will change from 3.967KN to 10.494KN if the cutting speed is between 1000mm/s and 2000mm/s for the pavement planer of BG2000.

Cutting forces analysis of micro-milling process on Inconel 718 – a finite element approach

2020 ◽  
Vol 11 (02) ◽  
pp. 2050011
Author(s):  
Padmaja Tripathy ◽  
Kalipada Maity
Keyword(s):  
Finite Element ◽  
Cutting Forces ◽  
Inconel 718 ◽  
Cutting Speed ◽  
Fem Analysis ◽  
Milling Process ◽  
Machining Process ◽  
Micro Milling ◽  
Depth Of Cut ◽  
Machining Parameters

This paper presents a modeling and simulation of micro-milling process with finite element modeling (FEM) analysis to predict cutting forces. The micro-milling of Inconel 718 is conducted using high-speed steel (HSS) micro-end mill cutter of 1mm diameter. The machining parameters considered for simulation are feed rate, cutting speed and depth of cut which are varied at three levels. The FEM analysis of machining process is divided into three parts, i.e., pre-processer, simulation and post-processor. In pre-processor, the input data are provided for simulation. The machining process is further simulated with the pre-processor data. For data extraction and viewing the simulated results, post-processor is used. A set of experiments are conducted for validation of simulated process. The simulated and experimental results are compared and the results are found to be having a good agreement.

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