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 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.

Statistical Cutting Force Model for Orthogonal Cutting of Polytetrafluoroethylene (PTFE) Composites

2013 ◽  
Author(s):  
Felicia Stan ◽  
Daniel Vlad ◽  
Catalin Fetecau
Keyword(s):  
Friction Coefficient ◽  
Cutting Force ◽  
Feed Rate ◽  
Normal Force ◽  
Polynomial Regression ◽  
Orthogonal Cutting ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Tool Geometry ◽  
Force Model

This paper presents an experimental investigation of the cutting forces response during the orthogonal cutting of polytetrafluoroethylene (PTFE) and PTFE-based composites using the Taguchi method. Cutting experiments were conducted using the L27 orthogonal array and the effects of the cutting parameters (feed rate, cutting speed and rake angle) on the cutting force were analyzed using the S/N ratio response and the analysis of variance (ANOVA). Statistical models that correlate the cutting force with process variables were developed using ANOVA and polynomial regression. The variation of the apparent friction coefficient was analyzed with respect to tool geometry and the cutting process. The results indicated that cutting and thrust forces increase with increasing feed rate, and decrease with increasing rake angles from negative to positive values and increasing cutting speed. A power law relationship between the apparent friction coefficient and the normal force exerted by the chip on the tool-rake face was identified, the former decreasing with an increasing normal force.

Study on the Influence of Anisotropy on Cutting Performance of Aviation Aluminium Alloy 7050-T7451

2020 ◽  
Vol 990 ◽  
pp. 29-35
Author(s):  
Hui Wang ◽  
Ying Meng ◽  
Duo Duo Li ◽  
Xiu Li Fu ◽  
Qi Hang Shi
Keyword(s):  
Aluminium Alloy ◽  
Orthogonal Cutting ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Cutting Performance ◽  
Rolled Sheet ◽  
Feed Speed ◽  
Aluminium Alloy 7050 ◽  
Degree Of Anisotropy ◽  
Forming Angle

Based on the hypocycloid theory, a highspeed orthogonal cutting simulation model was established. The cutting parameters (cutting speed, feed rate) and plane forming angle of the workpiece of aeronautical aluminium alloy 7050-T7451 pre-stretched rolled sheet were simulated and validated. The mapping relationship between cutting parameters, anisotropy and cutting performance was analyzed. The results show that the degree of anisotropy and the difficulty of material cutting are proportional to the forming angle, and the anisotropy decreases with the increase of cutting speed and the decrease of feed speed. Finally, the optimal cutting process range of aluminum alloy 7050-T7451 was obtained, which provides data support for highspeed cutting of anisotropic materials.

Temperature Field Numerical Analysis of Machining Process Based on the Finite Element Analysis

2014 ◽  
Vol 621 ◽  
pp. 611-616 ◽  
Author(s):  
Yan Juan Hu ◽  
Yao Wang ◽  
Zhan Li Wang
Keyword(s):  
Finite Element ◽  
Temperature Field ◽  
Metal Cutting ◽  
Orthogonal Cutting ◽  
Cutting Temperature ◽  
Cutting Parameters ◽  
Element Model ◽  
Machining Process ◽  
Element Analysis ◽  
Mechanical Coupling

In order to study the temperature field distribution in the process of machining, the finite element theory was used to establish the orthogonal cutting finite element model, and the key technologies were discussed simultaneously. By using ABAQUS software for cutting AISI1045 steel temperature field of numerical simulation, the conclusion about changing rule of cutting temperature field can be gotten. The results show that this method can efficiently simulate the distribution of temperature field of the workpiece, cutter and scraps, which is effected by thermo-mechanical coupling in metal work process. It provides the theory evidence for the intensive study of metal-cutting principle, optimizing cutting parameters and improving processing technic and so on.

The Study of Bone Cutting Force with FEM

2014 ◽  
Vol 974 ◽  
pp. 389-393 ◽  
Author(s):  
Sen Liu ◽  
Dong Mei Wu ◽  
Jun Zhao
Keyword(s):  
Finite Element ◽  
Cutting Force ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Element Model ◽  
Cutting Surface ◽  
On Line ◽  
Force Velocity ◽  
Optimization Of Cutting Parameters

In orthopedic surgery, it is easy to do harm to surrounding tissues, so the study of bone cutting is necessary. In this article, a finite element model (FEM) of orthogonal bone cutting is developed. Cutting force intra-operatively can provide the surgeon with additional on-line information to support him to control quality of cutting surface. The obtained cutting force decreased little with cutting speed increasing, but ascended evidently with cutting depth increasing. The results of finite element simulations are aimed at providing optimization of cutting parameters and the basic information for hybrid force-velocity control of a robot-assisted bone milling system.

Finite Element Analysis of Burr Formation in Micro-Machining

2014 ◽  
Vol 487 ◽  
pp. 225-229
Author(s):  
Juan Huang ◽  
Yong Hua Xiong ◽  
Jin Gui Huang ◽  
Gui Cheng Wang
Keyword(s):  
Finite Element ◽  
High Surface ◽  
Cutting Parameters ◽  
Burr Formation ◽  
Contact Friction ◽  
Tool Geometry ◽  
Work Piece ◽  
Micro Cutting ◽  
Finite Element Software ◽  
General Law

In the process of micro-cutting for the precision small parts, one of the main problems is the micro burrs. The finite element software Abaqus was used to simulate the micro-cutting process of aluminum 2024-T3. To create this model, Johnson-Cook (J-C) model was used to establish the material model, and Arbitrary Lagrangian Eulerian (ALE) method was used to separate the chip from work-piece. The contact friction models which was used between chip and tool was the modified Coulomb friction law. The formation process of micro burrs was simulated dynamically, and the effect of different cutting parameters and tool geometry parameters on burrs forming was analyzed. Furthermore, the general law was obtained. The results provide the guidance for optimizing the tool geometry parameters and cutting parameters to reduce the burrs in micro-cutting with the high surface quality.

FEA Simulation of the Influence of Cutting Parameters on Serrated Chip Formation in Machining Titanium Alloy Ti-6Al-4V

2012 ◽  
Vol 500 ◽  
pp. 152-156
Author(s):  
Zeng Hui Jiang ◽  
Ji Lu Feng ◽  
Xiao Ye Deng
Keyword(s):  
Titanium Alloy ◽  
Chip Formation ◽  
Orthogonal Cutting ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Element Model ◽  
Serrated Chip ◽  
Wide Range ◽  
Serrated Chip Formation ◽  
Fea Simulation

A finite element model of a two dimensional orthogonal cutting process is developed. The simulation uses standard finite software is able to solve complex thermo-mechanical problems. A thermo-visco-plastic model for the machined material and a rigid cutting tool were assumed. One of the main characteristic of titanium alloy is serrated shape for a wide range of cutting conditions. In order to understand the influence of cutting parameters on the chip formation when machining titanium alloy Ti-6Al-4V. The influence of the cutting speed,the cutting depth and the feed on the chip shape giving rise to segmented chips by strain localisation is respectively discussed.

Research on Temperature Field about Cutting Area in Plunge Milling Ti Alloy Based on Finite Element

2010 ◽  
Vol 102-104 ◽  
pp. 630-633
Author(s):  
Xu Da Qin ◽  
Wei Cheng Liu ◽  
Hao Jia ◽  
Xiao Lai Ji
Keyword(s):  
Thermal Conductivity ◽  
Finite Element ◽  
Temperature Field ◽  
Thermal Conductivity Coefficient ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Ti Alloy ◽  
Plunge Milling ◽  
Finite Element Software

Because of the small thermal conductivity coefficient of Ti alloy, the heat cannot disperse timely and accumulate seriously when plunge milling Ti alloy. If the cutting parameters can not be controlled well, the phenomenon of sticking will happen easily. According to the simulation and analysis of temperature field by using finite element software ABAQUS, the influence on cutting speed and feed for the Distributing of Temperature Field about Cutting Area in Plunge Milling Ti Alloy is acquired.

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.

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