scholarly journals Application of an Arbitrary Lagrangian–Eulerian Method to Modelling the Machining of Rigid Polyurethane Foam

Materials ◽  
2021 ◽  
Vol 14 (7) ◽  
pp. 1654
Author(s):  
Zdenek Horak ◽  
Petr Tichy ◽  
Karel Dvorak ◽  
Miloslav Vilimek
Keyword(s):  
Strain Rate ◽  
Cutting Speed ◽  
Maximum Temperature ◽  
Fe Model ◽  
Arbitrary Lagrangian Eulerian ◽  
Healthcare Applications ◽  
Ale Method ◽  
Damage Initiation ◽  
Constitutive Material Model ◽  
Cutting Speeds

Rigid polyurethane (PUR) foam, which has an extensive range of construction, engineering, and healthcare applications, is commonly used in technical practice. PUR foam is a brittle material, and its mechanical material properties are strongly dependent on temperature and strain rate. Our work aimed to create a robust FE model enabling the simulation of PUR foam machining and verify the results of FE simulations using the experiments’ results. We created a complex FE model using the Arbitrary Lagrangian–Eulerian (ALE) method. In the developed FE model, a constitutive material model was used in which the dependence of the strain rate, damage initiation, damage propagation, and plastic deformation on temperature was implemented. To verify the FE analyses’ results with experimentally measured data, we measured the maximum temperature during PUR foam drilling with different densities (10, 25, and 40 PCF) and at various cutting speeds. The FE models with a constant cutting speed of 500 mm/s and various PUR foam densities led to slightly higher Tmax values, where the differences were 13.1% (10 PCF), 7.0% (25 PCF), and 10.0% (40 PCF). The same situation was observed for the simulation results related to various cutting speeds at a constant PUR foam density of 40 PCF, where the differences were 25.3% (133 mm/s), 10.1% (500 mm/s), and 15.5% (833 mm/s). The presented results show that the ALE method provides a good match with the experimental data and can be used for accurate simulation of rigid PUR foam machining.

Finite Element Analysis of the Effect of Cutting Speed on the Orthogonal Turning of A359/SiCp MMC

2016 ◽  
Vol 852 ◽  
pp. 304-310
Author(s):  
M.M. Thamizharasan ◽  
Y.J. Nithiya Sandhiya ◽  
K.S. Vijay Sekar ◽  
V.V. Bhanu Prasad
Keyword(s):  
Finite Element ◽  
Matrix Material ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Fe Model ◽  
Element Analysis ◽  
Damage And Fracture ◽  
Orthogonal Turning ◽  
The Matrix ◽  
Cutting Speeds

The application of Metal Matrix Composite (MMC) has been increasing due to its superior strength and wear characteristics but the major challenge is its poor machinability due to the presence of reinforcement in the matrix which is a hindrance during machining. The material behaviour during machining varies with respect to input variables. In this paper the effect of cutting speed during the orthogonal turning of A359/SiCp MMC with TiAlN tool insert is analysed by developing a 2D Finite Element (FE) model in Abaqus FEA code. The FE model is based on plane strain formulation and the element type used is coupled temperature displacement. The matrix material is modeled using Johnson–Cook (J-C) thermal elastic–plastic constitutive equation and chip separation is simulated using Johnson–Cook’s model for progressive damage and fracture with parting line. Particle material is considered to be perfectly elastic until brittle fracture. The tool is considered to be rigid. The FE model analyses the tool interaction with the MMC and its subsequent effects on cutting forces for different cutting speeds and feed rates. The chip formation and stress distribution are also studied. The FE results are validated with the experimental results at cutting speeds ranging from 72 – 188 m/min and feed rates ranging from 0.111 – 0.446 mm/rev at constant depth of cut of 0.5mm.

scholarly journals A coupled thermo-mechanical model of friction stir welding

2012 ◽  
Vol 16 (2) ◽  
pp. 527-534 ◽  
Author(s):  
Darko Veljic ◽  
Milenko Perovic ◽  
Aleksandar Sedmak ◽  
Marko Rakin ◽  
Miroslav Trifunovic ◽  
...  
Keyword(s):  
Friction Stir Welding ◽  
Plastic Strain ◽  
Mechanical Model ◽  
Temperature Fields ◽  
Maximum Temperature ◽  
Bottom Surface ◽  
Al Alloy ◽  
Fe Model ◽  
Arbitrary Lagrangian Eulerian ◽  
Friction Stir

A coupled thermo-mechanical model was developed to study the temperature fields, the plunge force and the plastic deformations of Al alloy 2024-T351 under different rotating speed: 350, 400 and 450 rpm, during the friction stir welding (FSW) process. Three-dimensional FE model has been developed in ABAQUS/Explicit using the arbitrary Lagrangian-Eulerian formulation, the Johnson-Cook material law and the Coulomb?s Law of friction. Numerical results indicate that the maximum temperature in the FSW process is lower than the melting point of the welding material. The temperature filed is approximately symmetrical along the welding line. A lower plastic strain region can be found near the welding tool in the trailing side on the bottom surface. With increasing rotation speed, the low plastic strain region is reduced. When the rotational speed is increased, the plunge force can be reduced. Regions with high equivalent plastic strains are observed which correspond to the nugget and the flow arm.

Extension of Oxley’s Analysis of Machining to Use Different Material Models

2003 ◽  
Vol 125 (4) ◽  
pp. 656-666 ◽  
Author(s):  
Amir H. Adibi-Sedeh ◽  
Vis Madhavan ◽  
Behnam Bahr
Keyword(s):  
Strain Rate ◽  
Shear Zone ◽  
Shear Force ◽  
Cutting Speed ◽  
Chip Thickness ◽  
Shear Plane ◽  
Material Model ◽  
Shear Zones ◽  
Carbon Steels ◽  
Maximum Temperature

The aim of the present work is to extend the applicability of Oxley’s analysis of machining to a broader class of materials beyond the carbon steels used by Oxley and co-workers. The Johnson-Cook material model, history dependent power law material model and the Mechanical Threshold Stress (MTS) model are used to represent the mechanical properties of the material being machined as a function of strain, strain rate and temperature. A few changes are introduced into Oxley’s analysis to improve the consistency between the various assumptions. A new approach has been introduced to calculate the pressure variation along the alpha slip lines in the primary shear zone including the effects of both the strain gradient and the thermal gradient along the beta lines. This approach also has the added advantage of ensuring force equilibrium of the primary shear zone in a macroscopic sense. The temperature at the middle of the primary shear zone is calculated by integrating the plastic work thereby eliminating the unknown constant η. Rather than calculating the shear force from the material properties corresponding to the strain, strain rate and temperature of the material at the middle of the shear zone, the shear force is calculated in a consistent manner using the energy dissipated in the primary shear zone. The thickness of the primary and secondary shear zones, the heat partition at the primary shear zone, the temperature distribution along the tool-chip interface and the shear plane angle are all calculated using Oxley’s original approach. The only constant used to fine tune the model is the ratio of the average temperature to the maximum temperature at the tool-chip interface (ψ). The performance of the model has been studied by comparing its predictions with experimental data for 1020 and 1045 steels, for aluminum alloys 2024-T3, 6061-T6 and 6082-T6, and for copper. It is found that the model accurately reproduces the dependence of the cutting forces and chip thickness as a function of undeformed chip thickness and cutting speed and accurately estimates the temperature in the primary and secondary shear zones.

Numerical Analysis of Cutting With Chamfered and Worn Edge Tools

2000 ◽  
Author(s):  
Mohammad-R. Movahhedy ◽  
Yusuf Altintas ◽  
Mohamed S. Gadala
Keyword(s):  
High Speed ◽  
Cutting Speed ◽  
Cutting Edge ◽  
Maximum Temperature ◽  
Arbitrary Lagrangian Eulerian ◽  
Hard Materials ◽  
Ale Finite Element Method ◽  
Diffusion Wear ◽  
Dead Material ◽  
Chip Removal

Abstract In high-speed machining of hard materials, tools with chamfered edges and tool materials resistant to diffusion wear are commonly used. In this paper, the influence of cutting edge geometry on the chip removal process is studied through numerical simulation of cutting with sharp, chamfered or blunt edges and with carbide or CBN tools. The analysis is based on the use of arbitrary Lagrangian-Eulerian (ALE) finite element method, which makes it possible to analyze the cutting action without having to resort to node separation methods or remeshing. Simulations include cutting with tools of different chamfer angles at a range of cutting speeds and the numerical results are compared with experimental data obtained under similar cutting conditions. The study shows that a region of dead material zone is formed under the chamfer and acts as the effective cutting edge of the tool (in accordance with experimental observations). As a result, the chip formation process is not significantly affected by the presence of the chamfer. However, the forces, the thrust force in particular, are considerably increased. The effect of cutting speed on the process is also studied and is shown to produce a significant increase in maximum temperature on the rake face.

scholarly journals CAD-Based 3D-FE Modelling of AISI-D3 Turning with Ceramic Tooling

Machines ◽  
2021 ◽  
Vol 9 (1) ◽  
pp. 4
Author(s):  
Panagiotis Kyratsis ◽  
Anastasios Tzotzis ◽  
Angelos Markopoulos ◽  
Nikolaos Tapoglou
Keyword(s):  
Statistical Model ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Fe Model ◽  
Fe Modelling ◽  
3D Finite Element ◽  
Force Components ◽  
Four Levels ◽  
The Relationship ◽  
Strong Agreement

In this study, the development of a 3D Finite Element (FE) model for the turning of AISI-D3 with ceramic tooling is presented, with respect to four levels of cutting speed, feed, and depth of cut. The Taguchi method was employed in order to create the orthogonal array according to the variables involved in the study, reducing this way the number of the required simulation runs. Moreover, the possibility of developing a prediction model based on well-established statistical tools such as the Response Surface Methodology (RSM) and the Analysis of Variance (ANOVA) was examined, in order to further investigate the relationship between the cutting speed, feed, and depth of cut, as well as their influence on the produced force components. The findings of this study point out an increased correlation between the experimental results and the simulated ones, with a relative error below 10% for most tests. Similarly, the values derived from the developed statistical model indicate a strong agreement with the equivalent numerical values due to the verified adequacy of the statistical model.

scholarly journals Identification of the LLDPE Constitutive Material Model for Energy Absorption in Impact Applications

Polymers ◽  
2021 ◽  
Vol 13 (10) ◽  
pp. 1537
Author(s):  
Luděk Hynčík ◽  
Petra Kochová ◽  
Jan Špička ◽  
Tomasz Bońkowski ◽  
Robert Cimrman ◽  
...  
Keyword(s):  
Strain Rate ◽  
Material Model ◽  
Low Density Polyethylene ◽  
Low Density ◽  
Linear Low Density Polyethylene ◽  
Stress Strain ◽  
Rate Dependent ◽  
Constitutive Material Model ◽  
Principal Directions ◽  
Constitutive Material

Current industrial trends bring new challenges in energy absorbing systems. Polymer materials as the traditional packaging materials seem to be promising due to their low weight, structure, and production price. Based on the review, the linear low-density polyethylene (LLDPE) material was identified as the most promising material for absorbing impact energy. The current paper addresses the identification of the material parameters and the development of a constitutive material model to be used in future designs by virtual prototyping. The paper deals with the experimental measurement of the stress-strain relations of linear low-density polyethylene under static and dynamic loading. The quasi-static measurement was realized in two perpendicular principal directions and was supplemented by a test measurement in the 45° direction, i.e., exactly between the principal directions. The quasi-static stress-strain curves were analyzed as an initial step for dynamic strain rate-dependent material behavior. The dynamic response was tested in a drop tower using a spherical impactor hitting a flat material multi-layered specimen at two different energy levels. The strain rate-dependent material model was identified by optimizing the static material response obtained in the dynamic experiments. The material model was validated by the virtual reconstruction of the experiments and by comparing the numerical results to the experimental ones.

Failure mechanics analysis of AISI 4340 steel using finite element modeling of the milling process

2021 ◽  
pp. 030932472110580
Author(s):  
Muhammed Muaz ◽  
Sanan H Khan
Keyword(s):  
Finite Element ◽  
Failure Analysis ◽  
End Milling ◽  
Physical Phenomenon ◽  
Machining Process ◽  
Fe Model ◽  
Dissipation Energy ◽  
Damage Initiation ◽  
Milling Operation ◽  
Cutting Operation

A slot cutting operation is studied in this paper using a rotating/translating flat end milling insert. Milling operation usually comprises up-milling and down-milling processes. These two types of processes have different behaviors with opposite trends of the forces thus making the operation complex in nature. A detailed Finite Element (FE) model is proposed in this paper for the failure analysis of milling operation by incorporating damage initiation criterion followed by damage evolution mechanism. The FE model was validated with experimental results and good correlations were found between the two. The failure criteria field variable (JCCRT) was traced on the workpiece to observe the amount and rate of cutting during the machining process. It was found that the model was able to predict different failure energies that are dissipated during the machining operation which are finally shown to be balanced. It was also shown that the variation of these energies with the tool rotation angle was following the actual physical phenomenon that occurred during the cutting operation. Among all the energies, plastic dissipation energy was found to be the major contributor to the total energy of the system. A progressive failure analysis was further carried out to observe the nature of failure and the variation of stress components and temperature occurring during the machining process. The model proposed in this study will be useful for designers and engineers to plan their troubleshooting in various applications involving on-spot machining.

Thermal-Mechanical Effect on Temperature/Stress Distribution when Orthogonal Cutting Bearing Steel

2009 ◽  
Vol 407-408 ◽  
pp. 420-423
Author(s):  
He Ping Wang ◽  
Xue Ping Zhang
Keyword(s):  
Stress Distribution ◽  
Orthogonal Cutting ◽  
Cutting Speed ◽  
Chip Morphology ◽  
Bearing Steel ◽  
Mechanical Effect ◽  
Arbitrary Lagrangian Eulerian ◽  
Calculation Results ◽  
On Chip ◽  
Explicit Dynamic

An explicit dynamic coupled thermal-mechanical Arbitrary Lagrangian Eulerian (ALE) model was established to simulate orthogonal cutting AISI 52100 bearing steel, and its temperature and stress distribution. Based on ABAQUS, The ALE approach effectively simulates plastic flow around round edge of the cutting tool without employing chip separation criteria. The calculation results reveal that cutting speed and cutting depth have great impact on chip morphology, stress and temperature distribution in the finished surface and subsurface, the predicted temperature agrees well with experiment data obtained under the similar cutting conditions as well as the change in chip morphology from continuous to sawtooth as the cutting speed increases.

scholarly journals Analysis of the tool plunge in friction stir welding - comparison of aluminium alloys 2024 T3 and 2024 T351

2016 ◽  
Vol 20 (1) ◽  
pp. 247-254
Author(s):  
Darko Veljic ◽  
Bojan Medjo ◽  
Marko Rakin ◽  
Zoran Radosavljevic ◽  
Nikola Bajic
Keyword(s):  
Friction Stir Welding ◽  
Plastic Strain ◽  
Heat Generation ◽  
Aluminium Alloys ◽  
Three Dimensional ◽  
Equivalent Plastic Strain ◽  
Fe Model ◽  
Arbitrary Lagrangian Eulerian ◽  
Friction Stir ◽  
Tool Pin

Temperature, plastic strain and heat generation during the plunge stage of the friction stir welding (FSW) of high-strength aluminium alloys 2024 T3 and 2024 T351 are considered in this work. The plunging of the tool into the material is done at different rotating speeds. A three-dimensional finite element (FE) model for thermomechanical simulation is developed. It is based on arbitrary Lagrangian-Eulerian formulation, and Johnson-Cook material law is used for modelling of material behaviour. From comparison of the numerical results for alloys 2024 T3 and 2024 T351, it can be seen that the former has more intensive heat generation from the plastic deformation, due to its higher strength. Friction heat generation is only slightly different for the two alloys. Therefore, temperatures in the working plate are higher in the alloy 2024 T3 for the same parameters of the plunge stage. Equivalent plastic strain is higher for 2024 T351 alloy, and the highest values are determined under the tool shoulder and around the tool pin. For the alloy 2024 T3, equivalent plastic strain is the highest in the influence zone of the tool pin.

scholarly journals FINITE ELEMENT ANALYSIS OF THE HEAT TRANSFER IN A PISTON

2020 ◽  
Vol 4 (1) ◽  
pp. 45-51
Author(s):  
Aisha Muhammad ◽  
Shanono Ibrahim Haruna
Keyword(s):  
Heat Transfer ◽  
Finite Element ◽  
Numerical Simulations ◽  
Internal Combustion Engines ◽  
Thermal Stresses ◽  
Maximum Temperature ◽  
Cylinder Wall ◽  
Fe Model ◽  
Piston Cylinder ◽  
Piston Head

The gas expansion process that takes place in a piston cylinder assembly have been used in numerous applications. However, the time-dependent process of heat transfer is still not fully apprehended as the expansion processes are complex and difficult due to the unsteady property of the turbulent flow process. Internal combustion Engines(ICE) designs are conducted with the aim of achieving higher efficiency in the thermal characteristics. To optimize these designs, numerical simulations are conducted. However, modelling of the process in terms of heat transfer and combustion is complex and challenging. For a designer to understand, calculate and quantify the thermal stresses and heat losses at different sections of the structure, understanding the piston-cylinder wall is needed. This study carried out a numerical simulations based on Finite Element Method (FEM) to investigatethe stresses in the piston, and temperature after loading. Appropriate boundary conditions were set on different surfaces for FE model. The study includes the effects of the thermal conductivity of the material of piston, cylinder wall, and connecting rod. Results show the maximum Von-misses stress occurs on the piston head with a value of 3486. 1MPa. The maximum temperature of the piston head and cylinder wall stands at 68.252 and 42.704 degree Celsius respectively.

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