scholarly journals Experimental Investigation and Numerical Prediction of the Effects of Cutting Tool Geometry During Turning of AISI 316L Steel

2021 ◽  
Vol 65 (4) ◽  
pp. 293-301
Author(s):  
Amor Benmeddour
Keyword(s):  
Temperature Distribution ◽  
Residual Stresses ◽  
Cutting Force ◽  
Rake Angle ◽  
Tool Geometry ◽  
Model Parameters ◽  
Fe Model ◽  
Aisi 316L ◽  
Arbitrary Lagrangian Eulerian ◽  
The Impact

In this work, a numerical and an experimental study aimed to gain a better understanding of the impact of tool geometry such as (rake angle and cutting edge radius) on the temperature distribution and residual stresses in machining surface of AISI 316L stainless steel have been presented. To evaluate the experimental results, various experimental equipment was used, such as a conventional lathe to carry out the machining operations, the cutting force was measured using a Kistler dynamometer and X-ray diffraction technique was employed for determination of the residual stresses distribution on the machined surfaces. In addition, A thermo-mechanically coupled finite element (FE) analysis for cutting process is developed through ABAQUS code to predict the temperature distribution and residual stresses using an Arbitrary Lagrangian-Eulerian (ALE) approach. An inverse identification method has been used to determine the adequate Johnson-Cook (JC) material model parameters to obtain a good correlation between the cutting force measurements and numerical one. The FE model was then validated by comparison of the numerical results of residual stresses with experimental measurements for different tool geometries, which revealed a reasonable agreement.

FE Modeling of the Three-Layer Human Carotid Artery Under Impact Loadings

2007 ◽  
Author(s):  
Aihong Zhao ◽  
Ken Digges ◽  
Mark Field ◽  
David Richens
Keyword(s):  
Finite Element ◽  
Carotid Artery ◽  
Model Simulation ◽  
Material Model ◽  
Element Model ◽  
Traumatic Rupture ◽  
Aortic Tissue ◽  
Fe Model ◽  
Arbitrary Lagrangian Eulerian ◽  
The Impact

Blunt traumatic rupture of the carotid artery is a rare but life threatening injury. The histology of the artery is key to understanding the aetiology of this injury. The carotid artery is composed of three layers known as the tunica intima, media, and adventitia, with distinct biomechanical properties. In order to examine the behaviour of the carotid artery under external load we have developed a three layer finite element model of this vessel. A rubber-like material model from LS-DYNA was selected for the FE model. The Arbitrary-Lagrangian Eulerian (ALE) approach was adopted to simulate the interaction between the fluid (blood) and the structure (carotid). To verify the FE model, the impact bending tests are simulated using this FE model. Simulation results agree with tests results well. Furthermore, the mechanical behaviour of carotid artery tissues under impact loading were revealed by the simulations. The results provide a basis for a more in-depth investigation of the carotid artery in vehicle crashes. In addition, it provides a basis for further work on aortic tissue finite element modeling.

Simulation of High-Speed Cutting Process Based on ABAQUS

2011 ◽  
Vol 230-232 ◽  
pp. 1221-1225 ◽  
Author(s):  
Xia Yu ◽  
Xu Yao Sun ◽  
Dan Ke Wei
Keyword(s):  
High Speed ◽  
Chip Morphology ◽  
Material Model ◽  
Rake Angle ◽  
Cutting Process ◽  
Fe Model ◽  
High Speed Cutting ◽  
Line Technology ◽  
Chip Separation ◽  
The Impact

Using the separation line technology, established a FE model of two-dimensional cutting process for AISI4340 steel and discussed some basic theory and pivotal questions associated with the simulation of cutting process including the Johnson-Cook material model, the contact model between tool and chip, criteria of chip separation and so on. In order to study the impact of tool rake angle on the chip morphology and the cutting forces, the high-speed cutting process for AISI 4340 steel was simulated based on ABAQUS software. Also, analyzed the influence of mesh azimuth on the chip morphology and its temperature distribution.

Optimization of Cutter Geometry Features to Minimise Cutting Force on Machining Polyetheretherketone (PEEK) Engineering Plastic

2015 ◽  
Vol 761 ◽  
pp. 282-286 ◽  
Author(s):  
Raja Izamshah ◽  
Nurul Husna ◽  
Mohd Hadzley ◽  
Mohd Amran ◽  
Mohd Shahir Kasim ◽  
...  
Keyword(s):  
Cutting Force ◽  
Helix Angle ◽  
Rake Angle ◽  
Tool Geometry ◽  
Thermoplastic Material ◽  
Solid Carbide ◽  
End Mills ◽  
Geometry Feature ◽  
High Thermal Expansion ◽  
Optimal Values

Machining of thermoplastic material poses several challenges due to its low melting temperature and high thermal expansion which directly related to cutting force. Thus, controlling the cutting force and temperature is desirable for machining polyetheretherketone (PEEK). The cutting force is dependent on friction and shearing action produced by the tool. It is indicated the cutting force is significantly affected by tool cutter geometry. This paper aims to control the cutting force by optimizing the cutter geometries especially rake, clearance and helix angle on machining PEEK. The two –flutes of solid carbide ball nose end mills were used to conduct the experiments and the cutting force acquired was measured using piezoelectric dynamometer. Response Surface Methodology (RSM) approach was applied to design and analyse the optimal combination of tool geometry feature for machining PEEK. Based on obtained results, the best optimal values of tool geometry which contribute to minimum of cutting force were 17° rake angle, 26° of helix angle and 10° of clearance angle. The best control of tool geometry ultimately improves the cutting performance and reduces defect caused by high cutting forces.

Numerical and experimental investigation of the hole saw tool geometry effects on drilling of random chopped fiber composites

2021 ◽  
pp. 089270572110286
Author(s):  
Amira Hassouna ◽  
Slah Mzali ◽  
Farhat Zemzemi ◽  
Mohamed BenTkaya ◽  
Salah Mezlini
Keyword(s):  
Thrust Force ◽  
Rake Angle ◽  
Industrial Applications ◽  
Machining Process ◽  
Tool Geometry ◽  
Drilling Process ◽  
Fe Model ◽  
Glass Fiber Reinforced ◽  
Drilling Parameters ◽  
Damage Law

Drilling is the most widely used machining process in manufacturing holes in many industrial applications. Optimizing the drilling process is a key to improve the hole quality. Therefore, numerical modeling is an effective method that gives an idea about the cutting process to optimize the drilling parameters. This paper emphasizes the sensitivity of the thrust force, the torque and the machining-induced damage to the hole saw tool geometry using a 3D Finite Element (FE) model developed using ABAQUS/Explicit. A Johnson cook model associated with a ductile damage law is used to predict the failure mechanism of a random chopped glass fiber reinforced polyester. It is found that the thrust force, the torque and the damage around the hole obtained from the FE model are in good agreement with the experimental data. Differences of about 2% for the thrust force, 2.4% for the torque and 3% for the damage around the hole are observed. The results of the numerical model also indicated that the thrust force as well as the drilled workpiece quality are improved by choosing the suitable rake angle. A decrease of about 61% in the thrust force is observed when varying the rake angle from 0° to 20°. However, the latter has an insignificant effect on the thrust force. Furthermore, it can be concluded that this parameter highly influences the material removal process.

Optimal Selection of Tool Geometry by Finite Element Simulation

2007 ◽  
Vol 10-12 ◽  
pp. 702-706
Author(s):  
Sheng Wen Zhang ◽  
Chan Yuan Gong ◽  
Xi Feng Fang ◽  
Gui Cheng Wang
Keyword(s):  
Finite Element ◽  
Cutting Force ◽  
Finite Element Simulation ◽  
Cutting Temperature ◽  
Rake Angle ◽  
Cutting Process ◽  
Tool Geometry ◽  
Clearance Angle ◽  
Tool Geometries ◽  
Element Simulation

The effect of cutting tool geometry on cutting process is very prominent and cannot be ignored, especially the interactions between tool geometries. In this study, the effects of the rake angle, the clearance angle, the cutting edge radius and the interaction between rake angle and clearance angle on cutting force and cutting temperature are numerically investigated using finite element method. Four-factor three-lever orthogonal experimental design is adopted in the finite element simulation of orthogonal cutting process. An analysis of range is performed to identify significant trends in the cutting force and cutting temperature and the optimal level values of each factor. The result shows that the effect of the rake angle on cutting force is significant. The effect of interaction between rake angle and clearance angle on cutting temperature also appeared to be important. Finally, the optimal parameter combinations of tool geometries for cutting force and cutting temperature are obtained, respectively.

Investigation of tool geometry in nanoscale cutting single-crystal copper by molecular dynamics simulation

2019 ◽  
Vol 233 (8) ◽  
pp. 1208-1220 ◽  
Author(s):  
Houfu Dai ◽  
Hao Du ◽  
Jianbin Chen ◽  
Genyu Chen
Keyword(s):  
Molecular Dynamics ◽  
Single Crystal ◽  
Cutting Force ◽  
Rake Angle ◽  
Tool Geometry ◽  
Single Crystal Copper ◽  
Clearance Angle ◽  
Edge Radius ◽  
Lower Temperature ◽  
Nanoscale Cutting

Molecular dynamics has been employed in this paper to investigate the nanoscale cutting process of single-crystal copper with a diamond tool. The behavior of the workpiece during material removal by diamond cutting has been studied. The effects of tool geometry including rake angle, clearance angle, and edge radius are thoroughly investigated in terms of chips, dislocation movement, temperature distribution, cutting temperature, cutting force, and friction coefficient. The investigation showed that an appropriate positive rake angle ([Formula: see text]), a suitable clearance angle ([Formula: see text]), or a smaller edge radius tip resulted in a smaller cutting force and a better subsurface finish. It was found that a tool with a rake angle of [Formula: see text] generated more chips, had a higher cutting efficiency, and produced a lower temperature in the workpiece, but a smaller rake angle tip was more conducive to protecting the groove compared to a large rake angle tip. Compared with a tool with a small clearance angle, the tool with a larger clearance angle generated more chips and caused a lower temperature rise in the copper workpiece, and prolonged its lifetime. In addition, a larger clearance angle tip was more conducive to protecting the groove. A smaller edge radius tip reduces the cutting heat during the nanoscale cutting process, while the volume of chips decreases. These results indicated that it is possible to control and adjust the tool parameters according to the tool rake angle, clearance angle, and edge radius during the machining of single-crystal copper, and a set of tool parameters were obtained: [Formula: see text] rake angle, [Formula: see text] clearance angle, and 0 nm edge radius which could reduce surface damage and the required cutting force.

Experimental Investigation on Cutting Performance of Face Milling Cutter

2012 ◽  
Vol 217-219 ◽  
pp. 2133-2137
Author(s):  
Bing Yan ◽  
Yang Li ◽  
Wei Wang ◽  
Hao Feng
Keyword(s):  
Cutting Force ◽  
High Speed ◽  
Cutting Parameters ◽  
Rake Angle ◽  
Tool Geometry ◽  
Depth Of Cut ◽  
Machined Surface ◽  
High Speed Cutting ◽  
Angle Effect ◽  
Axial Depth

The cutting tool geometry and cutting parameters have a great impact on cutting force, while cutting force is an important factor which affecting the tool life. High speed cutting experiments have shown that when slight axial depth of cut is adopted, rake angle effect on main cutting force significantly. When cutting aluminum alloy, the roughness of machined surface decrease with increasing tool rake angle. The axial depth of cut does not have a big influence on machined surface ’s roughness.

Surface contour error model of five-axis machining considering multifactor coupling effects

2021 ◽  
pp. 095440622110058
Author(s):  
Shuyi Ge ◽  
Liping Wang ◽  
Guang Yu
Keyword(s):  
Cutting Force ◽  
Calculation Method ◽  
Flank Milling ◽  
Contour Error ◽  
Fe Model ◽  
Surface Contour ◽  
Cantilever Structure ◽  
Multifactor Coupling ◽  
Five Axis ◽  
The Impact

During five-axis flank milling procedure, the static deflection of workpiece and cutter creates surface errors that lead to defects in projects with strict requirements, especially in thin-walled parts industry. Focusing on the mentioned issues, the surface contour error is predicted in this paper considering the coupling between the deflection and cutting force. First, an efficient calculation method of the cutting force is presented in five-axis flank milling. This method accounts for the impact of cutter runout on cutter/workpiece engagement (CWE) and the instantaneous undeformed chip thickness (IUCT). Then, a cutter is modelled as a cantilever structure and thus an analytical solution for the deflection of the end mill can be obtained. Next, the flexible cutting force is distributed on a finite element (FE) model of workpiece, while the workpiece stiffness keeps varying with the material removal. Subsequently, a flexible iterative calculation method for achieving deflection prediction is established. Finally, the prediction model is proven by machining tests of an S-shaped specimen in which predicted values of the surface error match with the experimental results.

scholarly journals COMPARISON OF PARAMETERS OF SURFACE INTEGRITY OF MACHINED DUPLEX AND AUSTENITE STAINLESS STEELS IN RELATION TO TOOL GEOMETRY

2017 ◽  
Vol 9 ◽  
pp. 1
Author(s):  
Jiří Čapek ◽  
Zdeněk Pitrmuc ◽  
Kamil Kolařík ◽  
Libor Beránek ◽  
Nikolaj Ganev
Keyword(s):  
Residual Stresses ◽  
Surface Integrity ◽  
Rake Angle ◽  
Optical Microscope ◽  
Hole Drilling ◽  
Tool Geometry ◽  
X Ray Diffraction ◽  
X Ray ◽  
Hole Drilling Method ◽  
Drilling Method

The goal of this contribution was to describe parameters of surface integrity of two machined materials; austenite and duplex stainless steel. Residual stresses and presence of straininduced martensite were studied as a function of the side rake angle. Residual stresses of surface and sub-surface layers were determined using X-ray diffraction techniques and hole-drilling method. By using X-ray diffraction, it is possible to determine residual stresses in each phase separately, in comparison with hole-drilling method. The presence of strain-induced martensite was investigated using Barkhausen noise and optical microscope.

Investigation of the Impact of Cutting Parameters on Surface Integrity in the End Milling of Inconel 625

2019 ◽  
Vol 969 ◽  
pp. 762-767 ◽  
Author(s):  
Ramesh Rajguru ◽  
Hari Vasudevan
Keyword(s):  
Residual Stresses ◽  
Surface Integrity ◽  
Cutting Parameters ◽  
Rake Angle ◽  
Inconel 625 ◽  
Micro Hardness ◽  
Machined Surface ◽  
Radial Rake Angle ◽  
Radial Depth ◽  
The Impact

Nickel based super alloys, such as Inconel 625 is amongst the most difficult to machine, due to its low thermal conductivity and high strength at higher temperature. Although, they are used in aerospace exhaust systems and other applications, the strain hardening that results during the machining operation, which adversely affects surface integrity of machined surface of such materials especially in extensive applications, is a cause for concern. In this context, this study was carried out, involving the milling operation, using solid carbide tools coated with TiAlSiN, under specifically developed conditions for dry machining of the difficult to cut materials. The cutting parameters were 4 in number, namely radial rake angle, feed per tooth, cutting speed and radial depth of cut and the response parameters included surface integrity characteristics, such as residual stresses, surface roughness and micro-hardness. Based on the experimental analyses, it was found that the micro-hardness of machined surface was higher. Micro hardness of sub surface decreases with the depth (50,100,150,250μm) due to a reduction in the work hardening of the Inconel 625, underneath the surface layer. The residual stresses were analyzed using main effect plot, and it was seen that the residual stresses were significantly influenced by the radial rake angle, followed by feed per tooth.

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