Papers by Keyword: Orthogonal Machining

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Authors: Tao Wang, Li Jing Xie, Xi Bin Wang
Abstract: The aim of this paper is to compare the predicting ability of the orthogonal cutting models developed by three commonly used finite element softwares, namely commercial explicit dynamic code Abaqus/explicit, Thirdwave AdvantEdge and implicit finite element codes Deform 2D. In all proposed models, the chip formation was simulated through adaptive remeshing and plastic flow of work material around the round edge of the cutting tool. Therefore, there was no need for a chip separation criterion which made the physical process simulation more realistically. Predicted cutting, feed force and shear angle were compared with experimental results. In addition, the effect of friction coefficient on the chip morphology was investigated as well.
Authors: Fang Juan Zhou, Xue Lin Wang, Yu Jin Hu
Abstract: A new modified model based on the non-parallel primary shear zone is presented in this paper. Experiments showed that the primary shear zone in cutting process wasn’t an absolutely parallel-sided zone. In fact, there are small inclined angles in the primary shear zone. Therefore, in this paper, a correction coefficient is proposed to predict cutting forces exactly. The coordinate mapping approach is adopted to obtain the correction coefficient and the software MATLAB is utilized to predict cutting forces. The material of stainless steel 316L is used to validate the modified model. By comparison between predicted analysis and experimental results, the proposed model shows good agreements with experiments.
Authors: S. Mohammadi, R. Adibi-Asl, M. Vaz
Authors: Hui Xia Liu, H. Yan, Xiao Wang, Shu Bin Lu, K. Yang, Lan Cai
Abstract: Two 3-D finite element models of coated tool and uncoated tool were established using the finite element code DEFORM-2D based on the updated Lagrangian formula. And their machinability on high speed orthogonal machining was simulated and compared. The investigation results indicate that the coated tool has higher surface temperature and lower inside temperature compared with the uncoated tool. Moreover, the cutting forces of the model using coated tool are lower than that using uncoated tool.
Authors: S. Sriram, V. Vignesh, K.S. Vijay Sekar, Murugasan Pradeep Kumar
Abstract: The present work aims in creating the Finite Element Models for the conventional and the Cryogenic Orthogonal machining process. Finite Element Modelling (FEM) of the orthogonal machining operation was performed using DEFORM – 2D which is based on a modified Lagrangian formulation. Finite Element models were developed for various experimental conditions for both conventional and cryogenic orthogonal machining process. The response variables obtained from the models are cutting force, thrust force, temperature, shear stress, strain and strain rate. AISI 1045 steel is used as work material and for tool, tungsten carbide is used under various experimental conditions with the cutting speeds at 100 m/min, 150 m/min, 200 m/min and feeds at 0.07 mm/rev, 0.1 mm/rev, 0.14 mm/rev. A maximum temperature difference of 20.12% is obtained when conventional and cryogenic models were compared at a feed rate of 0.07 mm/rev and cutting speed of 150 m/min. cutting force and thrust force were higher for cryogenic model compared with that of the conventional model. Stress and Strain were distributed as expected to occur in the experiment.
Authors: Sekar K.S. Vijay, Kumar M. Pradeep
Abstract: Flow stress is a vital input data for machining simulations, which is experimentally measured from Split Hopkinson pressure bar (SHPB) tests. However such flow stress does not fit machining conditions of strain, strain rate and temperatures and lead to serious simulation errors. In this research work an integrated Taguchi – Finite element (FE) methodology is adopted to optimize the flow stress of AISI 1045 steel material for orthogonal machining. The flow stress computed from the optimization approach along with thermo physical material properties are input into the FE code. The FE cutting forces and chip thickness ratio (CTR) showed an improvement of 6-8% and 2-4% over conventional Johnson – Cook (JC) models. An optimum set of JC model parameters were found from the study. The JC parametric analysis indicated high cutting force sensitivity to yield strength and CTR sensitivity to yield strength, strain hardening and thermal softening.
Authors: Su Yu Wang, Jun Zhao, Hui Meng, Xing Ai, Z.L. Li
Abstract: This paper proposes a numerical cutting model with the FEM to simulate the temperature field at the contact zone on the tool rake face. The analysis of the tool rake face temperature in orthogonal machining is studied based on heat transfer theory and calculus of variation. Then, the FEM simulation results of the temperature field on the rake face in various cutting speeds and the cutting speeds vs peak temperature curves are given. The results show that the highest temperature of the tool surface is located at a distance nearby the tool tip, and the higher cutting speeds can increase the tool rake face temperature obviously. In addition, the workpiece materials have a great effect on the peak temperatures at the rake face. Therefore, this study is helpful to investigate tool wear mechanism and optimize the machining parameters for the metal cutting processes.
Authors: Sekar K.S. Vijay, Kumar M. Pradeep
Abstract: Numerical simulations in machining processes are dependent on the flow stress input data. The flow stress is computed from empirical models which depend on number of material parameters, the values of which are derived from various mathematical optimization techniques. The derived flow stress parameters vary based on the nature of techniques used and the flow stress testing procedure utilized. This results in variations in the numerical simulation results when working with different models. In this work, the Johnson Cook flow stress model is tested for its sensitivity towards the finite element (FE) results. Orthogonal turning is conducted with AA 6082 (T6) aluminium alloy and the process is simulated in Deform 2D. The flow stress computed from the Johnson Cook model is input to the FE code and the cutting force and chip thickness recorded. The FE results are input to the Minitab statistical code and an optimization process conducted based on the orthogonal arrays concept. The comparative study reveals the sensitivity of the five parameters of the material model towards the cutting force and chip thickness.
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