CEL FEM Investigation of Effects of Microgrooved Cutting Tools in High Speed Machining of AISI 1045 Steel

2017 ◽  
Author(s):  
Han Wu ◽  
Nick H. Duong ◽  
J. Ma ◽  
Shuting Lei
Keyword(s):  
Cutting Force ◽  
High Speed ◽  
Cutting Tools ◽  
Cutting Temperature ◽  
Chip Morphology ◽  
High Speed Machining ◽  
Rake Face ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
1045 Steel

In this paper, the commercial FEM software package Abaqus is used to investigate the effects of microgrooved cutting tools in high speed orthogonal cutting of AISI 1045 steel. Microgrooves are designed and fabricated on the rake face of cemented carbide (WC/Co) cutting inserts. A coupled Eulerian-Lagrangian (CEL) finite element model is developed based on Abaqus to solve the evolution of the cutting temperature, chip morphology, cutting force, and phase constitutes simultaneously. This model is validated by comparing the numerical results with the experimental data for orthogonal high speed cutting of AISI 1045 steel with various cutting conditions. In addition, this model is also validated by comparing with the experimental data of regular tool and microgrooved cutting tool under the cutting speed of 120m/min. This validated CEL FEM model is then utilized to investigate the effects of microgrooved cutting tools on the phase transformation, cutting force, cutting temperature, and chip morphology in high speed orthogonal cutting of AISI 1045. The effects of microgroove width, edge distance (the distance from cutting edge to the first microgroove), and microgroove depth are examined and assessed in terms of cutting force, cutting temperature, chip morphology, and phase transformation. It is found that this CEL FEM model can capture the essential features of orthogonal high speed cutting of AISI 1045 using microgrooved cutting tools. It is also concluded that microgrooved cutting tools can not effectively reduce the cutting force in high speed machining, which is contrary to the conclusion obtained for low speed machining in previous research. However, microgrooves on the rake face have influence on the austenite percentage in the chip near the rake face. This research provides insightful guidance for optimizing the cutting performance in terms of cutting temperature, cutting force, chip morphology, and phase transformation in high speed machining of AISI 1045 steel.

Investigation of the Effects of Microgrooved Cutting Tool in High Speed Machining of AISI 1045 Steel

2017 ◽  
Author(s):  
Xingbang Chen ◽  
Nick H. Duong ◽  
J. Ma ◽  
Shuting Lei
Keyword(s):  
Cutting Force ◽  
High Speed ◽  
Cutting Tool ◽  
Cutting Tools ◽  
Contact Length ◽  
High Speed Machining ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
Cutting Inserts ◽  
1045 Steel

In this paper, numerical investigation of the effects of microgroove textured cutting tools in high speed machining of AISI 1045 is conducted using Finite Element Method (FEM). Microgrooves are designed and fabricated on the rake face of cemented carbide (WC/Co) cutting inserts. The effects of microgroove width, edge distance (the distance from cutting edge to the first microgroove), and microgroove depth are examined and assessed in terms of main cutting force, thrust force, and tool-chip contact length. It is found that microgrooved cutting tools generate lower cutting force and consequently lower the energy necessary for machining. This research provides insightful guidance for optimizing tool life and reducing energy consumption in high-speed machining of AISI 1045 steel.

A Metallo-Thermomechanically Coupled Analysis of Orthogonal Cutting of AISI 1045 Steel

2012 ◽  
Vol 134 (5) ◽  
Author(s):  
Hongtao Ding ◽  
Yung C. Shin
Keyword(s):  
Experimental Data ◽  
Cutting Force ◽  
Orthogonal Cutting ◽  
Cutting Temperature ◽  
Chip Morphology ◽  
Machining Process ◽  
Coupled Analysis ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
1045 Steel

Materials often behave in a complicated manner involving deeply coupled effects among stress/stain, temperature, and microstructure during a machining process. This paper is concerned with prediction of the phase change effect on orthogonal cutting of American Iron and Steel Institute (AISI) 1045 steel based on a true metallo-thermomechanical coupled analysis. A metallo-thermomechanical coupled material model is developed and a finite element model (FEM) is used to solve the evolution of phase constituents, cutting temperature, chip morphology, and cutting force simultaneously using abaqus. The model validity is assessed using the experimental data for orthogonal cutting of AISI 1045 steel under various conditions, with cutting speeds ranging from 198 to 879 m/min, feeds from 0.1 to 0.3 mm, and tool rake angles from −7 deg to 5 deg. A good agreement is achieved in chip formation, cutting force, and cutting temperature between the model predictions and the experimental data.

Assessment of Restricted Contact Cutting Tool in Dry Machining of AISI 1045 Steel

2014 ◽  
Author(s):  
J. Ma ◽  
Xianchen Ge ◽  
Nick H. Duong ◽  
Shuting Lei
Keyword(s):  
Cutting Force ◽  
Cutting Tool ◽  
Thrust Force ◽  
Alpha Angle ◽  
Cutting Tools ◽  
Rake Face ◽  
Edge Radius ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
1045 Steel

This paper studies the performance of restricted cutting tool in dry orthogonal machining of mild steel (AISI 1045 steel) using finite element simulations. The rake face of cemented carbide (WC/Co) cutting inserts is designed and the rake face length is shortened. The purpose is to examine the effect of shortened tools on machining performance and to compare it with regular cutting tools. The following restricted tool parameters are examined: length of rake face, alpha angle (the angle between the rake face and the supporting face), and edge radius. Their effects are assessed in terms of the main force, thrust force, and chip-tool contact length. It is found that restricted cutting tools generate lower cutting force and thrust force and consequently lower the energy necessary for machining. The length of rake face, the angle between the rake face and the supporting face, and edge radius all have influence on cutting force in their own ways. The effects of these three parameters on the tool temperature distribution are also investigated.

A Metallo-Thermo-Mechanically Coupled Analysis of Orthogonal Cutting of AISI 1045 Steel

2012 ◽  
Author(s):  
Hongtao Ding ◽  
Yung C. Shin
Keyword(s):  
Experimental Data ◽  
Cutting Force ◽  
Orthogonal Cutting ◽  
Cutting Temperature ◽  
Chip Morphology ◽  
Machining Process ◽  
Coupled Analysis ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
1045 Steel

Materials often behave in a complicated manner involving deeply coupled effects among stress/stain, temperature and microstructure during a machining process. This paper is concerned with prediction of the phase change effect on orthogonal cutting of AISI 1045 steel based on a true metallo-thermo-mechanical coupled analysis. A metallo-thermo-mechanical coupled material model is developed, and a finite element model is used to solve the evolution of phase constituents, cutting temperature, chip morphology, and cutting force simultaneously using ABAQUS. The model validity is assessed using the experimental data for orthogonal cutting of AISI 1045 steel under various conditions, with cutting speeds ranging from 198 to 879 m/min, feeds from 0.1 to 0.3 mm, and tool rake angles from −7° to 5°. A good agreement is achieved in chip formation, cutting force and cutting temperature between the model predictions and the experimental data.

High Speed Machining of Hardened AISI 1045 Steel

2016 ◽  
Vol 861 ◽  
pp. 63-68 ◽  
Author(s):  
Xue Ping Zhang ◽  
Shu Biao Wu ◽  
Zhen Qiang Yao ◽  
Li Feng Xi
Keyword(s):  
High Speed ◽  
Shear Bands ◽  
Chip Morphology ◽  
Machining Parameters ◽  
Chip Breaker ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
High Feed ◽  
Serrated Chips ◽  
1045 Steel

Hardened AISI 1045 steel implemented in machine tool spindle was previously ground using grinding operation. This research aims to address the feasibility of hard turning AISI 1045 using PCBN tool with chip breaker under dry condition. Chip morphology, cutting force and temperature were measured, analyzed and correlated with machining parameters. Experimental results demonstrate that serrated chips are generated at high speeds, high feed rate is an assistant to promote serrated chips, and chip breaker can help break chip into acceptable lengths. Cutting forces were characterized with periodic fluctuation along three directions as chips are serrated. Temperature at machined zone can reach as high as 1200°C, which indicates that adiabatic shear bands can be successfully achieved during the machining of hardened AISI 1045 steel without applying lubricants.

Tribological and Thermal Effects of Cutting Fluid Application in Machining With Coated and Grooved Cutting Tools

2005 ◽  
Author(s):  
Anshu D. Jayal ◽  
A. K. Balaji
Keyword(s):  
Cutting Tools ◽  
Chip Morphology ◽  
Cutting Fluid ◽  
Machining Performance ◽  
Chip Breaking ◽  
Tool Coatings ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
Application Methods ◽  
1045 Steel

The use of Cutting Fluids (CFs) in machining operations is being increasingly questioned in recent years for environmental and economic reasons, leading to efforts in promoting dry, as well as minimal quantity of lubricant (MQL), machining. However, the tribological effectiveness and thermal aspects of CF action at modern cutting conditions, which not only involve relatively high cutting speeds but also advanced tool coatings and chip-breaking geometric features, need better understanding. This paper presents an experimental investigation into the effects of different CF application methods on various machining performance measures while cutting with commercially available flat-faced, as well as grooved, uncoated and coated cemented tungsten carbide tools. CF effects under dry, flood, and MQL conditions, were gauged through their influence on cutting forces, tool temperatures, tool-chip interfacial contact, and chip morphology during machining of AISI 1045 steel. The results show new trends on the individual cooling and lubricating effects of CF application methods, and the effects of their interactions with the tool coatings and the presence/absence of chip-breaking grooves.

Assessment of the Performance of Microbumped Cutting Tool in Machining of AISI 1045 Steel

2014 ◽  
Author(s):  
J. Ma ◽  
Nick H. Duong ◽  
Shuting Lei
Keyword(s):  
Cutting Force ◽  
Cutting Tool ◽  
Thrust Force ◽  
Cutting Tools ◽  
Contact Length ◽  
Machining Performance ◽  
Edge Distance ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
1045 Steel

This paper investigates the performance of microbump textured cutting tool in dry orthogonal machining of mild steel (AISI 1045 steel) using AdvantEdge finite element simulation. Microbumps are designed on the rake face of cemented carbide (WC/Co) cutting inserts. The purpose is to examine the effect of microbump textured tools on machining performance and to compare it with non-textured regular cutting tools. Specifically, the following microbump parameters are examined: microbump width, microbump height, and edge distance (the distance from cutting edge to the first microbump). Their effects are assessed in terms of the main force, thrust force, and chip-tool contact length. It is found that microbump textured cutting tools generate lower cutting force and thrust force and consequently lower the energy consumption for machining. The micobump width, microbump height, and edge distance all have influence on cutting force in their own ways.

Finite Element Simulation and Experiment of Chip Formation during High Speed Cutting of Hardened Steel

2010 ◽  
Vol 29-32 ◽  
pp. 1838-1843 ◽  
Author(s):  
Chun Zheng Duan ◽  
Hai Yang Yu ◽  
Yu Jun Cai ◽  
Yuan Yuan Li
Keyword(s):  
Finite Element ◽  
Cutting Force ◽  
High Speed ◽  
Chip Morphology ◽  
Hardened Steel ◽  
High Speed Machining ◽  
Serrated Chip ◽  
High Speed Cutting ◽  
Element Simulation ◽  
Aisi 1045

As an advanced manufacturing technology which has been developed rapidly in recent years, high speed machining is widely applied in many industries. The chip formation during high speed machining is a complicated material deformation and removing process. In research area of high speed machining, the prediction of chip morphology is a hot and difficult topic. A finite element method based on the software ABAOUS which involves Johnson-Cook material model and fracture criterion was used to simulate the serrated chip morphology and cutting force during high speed cutting of AISI 1045 hardened steel. The serrated chip morphology and cutting force were observed and measured by high speed cutting experiment of AISI 1045 hardened steel. The effects of rake angle on cutting force, sawtooth degree and space between sawteeth were discussed. The investigation indicates that the simulation results are consistent with the experiments and this finite element simulation method presented can be used to predict the chip morphology and cutting force accurately during high speed cutting of hardened steel.

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