Papers by Keyword: Finite Element (FE) Simulation

Abstract: Stress harps with bars of different size were used to study residual stresses due to different cooling rate during casting of a grey iron. Finite element (FE) simulations were performed to predict residual stresses from the casting process and the effect of a stress relieving heat treatment. Intended for validating the simulations, neutron diffraction (ND) and hole drilling methods were used to measure the residual stress distribution through the thickness and in a thin surface layer, respectively. Good agreement between the FE simulations and ND measurements is observed for the annealed harp and the normal and transverse directions of the as cast harp. Discrepancy occurs in the axial direction and especially in the side bars of the as cast harp for which the simulation shows much higher compressive residual stresses. The observed difference between the different techniques was discussed with respect to the characteristics of the different methods.

Abstract: In traditional model of high-speed cutting, each modeling or modify process, material parameters input, boundary conditions set take up a lot of time, the solution process has blindness and not easy to operate. this article uses the python language, based on ABAQUS to secondary development of cutting simulation model in pre-treatment, establish exclusive two-dimensional cutting simulation interface, realization the parametric settings of tool angle, the size of the tool and the workpiece, cutting parameters, parametric design can shorten the time of modeling, and lay the foundation for the establishment of the high efficiency and high accuracy of the simulation model.

Abstract: This paper analyzed the serrated chip formation process and mechanism in high-speed milling of nickel-based superalloy GH706. Firstly, analyzed two theories of serrated chip formation: cyclical fracture theory and adiabatic shear theory. Secondly, used the simulation of chip formation in high-speed milling of GH706 process, and concluded that the two major theories have achieved dialectical unity when machining for such difficult machining materials. Finally experiments for serrated chip, when cutting speed exceeded 200/min, serrated chips became more obvious. Research has shown that for nickel-based superalloy, adiabatic shear instability of the unstable thermoplastic in the first deformation zoon become the leader of formation of serrated chip, followed as the speed increases, fracture aggravate the degree of serrated chip.

Abstract: Targeting the current status of cutting tool design long cycle and inefficient, this research presents an integrating system of cutting tool design (CAD) and simulation (CAE). First, the paper proposes the system architecture and analyzes the process. And then based on the architecture, the system prototype integrating SIEMENS NX and ANSYS is developed on the Visual Studio 2008 platform. The prototype can generate cutting tool 3D model on SIEMENS NX and continue to simulate on ANSYS based on the information from users. Finally, a kind of ball end mill is presented to certificate this system.

Abstract: Application prospect of the high volume fraction SiCp/Al composites becomes increasingly widespread, the study of cutting mechanism is important for achieving its high efficient and precision machining. In this paper, a three-dimensional beveled simulation model of high volume fraction SiCp/Al composites on high-speed milling is established by finite element software ABAQUS, the constitutive on model material, the tool-chip contact and the chip separation model is elected reasonably.The paper analyzes the effect of cutting speed on the chip formation and the stress distribution of the material. The results shows that: with the increasing of cutting speed, the chip is easily broken, cutting speed have little impact on the maximum stress of the material.

Abstract: In this paper, based on finite element software DEFORM, the model of a large cutting depth and quasi-high speeds milling of titanium alloys is built to study the cutting temperature and cutting force variation along with the change of cutting parameters. The simulation results show that: the location of the maximum cutting temperature appears in the cutting edges of the tool nose circular profile. Meanwhile, due to workpiece material rebound in the cutting process, the interface between workpiece and tool flank face occurs serious extrusion, which results in relatively high cutting temperature on the workpiece machined surface. In addition, cutting speed and feed rate per tooth play a key role in influencing the cutting temperature. However, the influence of cutting depth on the cutting temperature is less clear. With the increase in the feed rate and depth of cut, cutting force increased significantly. In particular, within the scope of the cutting speeds under the given conditions, the cutting force has a tendency to decrease with the cutting speed increasing over 120m/min.

Abstract: Dynamic cutting force will induce vibrations in hardened steel precision turning process. The dynamic cutting force in the process of turning was studied, and the dynamic cutting force model of hardened steel precision turning system was set; Based on DEFORM-3D software, a three-dimensional model of hardened steel turning was established by pre-set some fluctuations workpiece geometry; the turning test of hardened steel GCr15 in CAK6150DI lathe by using PCBN cutting tools, simulation and experimental results show that the high-speed precision turning will produce strip and sawtooth chip morphology; the maximum cutting force of hardened steel precision turning is the radial cutting force, which is greater than the main cutting force; cutting forces have a larger amount of fluctuation, which can reach 30% -55%. This research will provide a theoretical basis for related study on the vibration of the hardened steel turning process

Abstract: In order to better study hardened steel cutting process, we should model and simulate the process of cutting hardened steel by DEFORM-3D on the basis of applying finite element method to analyze the influence of cutting speed and feed to main cutting force, cutting heat and stress. Study shows that the cutting speed and feed is an important factor to determine the main cutting force. Cutting heat affects the physical properties of metal materials as a product of the energy conversion. The distribution of equivalent stress decided to point the strength of the cutting performance in different region. Reasonable utilization of cutting speed, feed processing has important significance for practical production on the premise of to ensure good cutting tool performance.

Abstract: Integral impeller is the key component in aviation, aerospace and other fields, and the deformation has an important effect to the machining quality and precision of the integral impeller. Because of the complexity of the geometry and surface curvature changes for the integral impeller, and the semi suspended state during the processing, force analysis and control technology for the deformation have become the key and difficulty to realize high quality processing. In this paper, the situation about the blade machining with the finite element analysis is introduced, and the factors about the blade machining deformation is also summarized. The deformation of a single cutter location point are computed and analyzed with finite element method, and the application problems to the machining deformation with the finite element are presented.

Abstract: Based on the application of Rock Bolt Foundation in metallurgical industrial plant foundation design, this paper utilized bolt deformation formulas that derived by Gu Shuancheng and others to calculate deformation of rock blot. The result is consistent with the experimental value, the authors can further verify the experimental and theoretical calculation value eventually by finite element analysis software ANSYS, which provides a reference for practical application of rock bolt foundation in metallurgical industrial plant.