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Finite element simulation and experimental validation of the effect of tool wear on cutting forces in turning operation

Wybrane pełne teksty z tego czasopisma
Identyfikatory
Warianty tytułu
Języki publikacji
EN
Abstrakty
EN
Machining is the most widely used process in manufacturing, and tool wear plays a significant role in machining efficiency and effectiveness. There is a continuous requirement to manufacture high-quality products at a lower cost. Many past researches show that variations in tool geometry affect the cutting forces significantly. The increase in cutting forces leads to excessive vibrations in the system, giving a poor surface finish to the machined product. In this work, a 2D coupled thermo-mechanical model is developed using Abaqus/Explicit to predict the cutting forces during turning of mild steel. Johnson-Cook material model along with damage model has been used to define the material behavior. Coulomb’s friction model is considered for defining the interaction between the tool and the work piece.Metal cutting process is simulated for different sets of cutting conditions and compared with experimental results. The finite element method results correlatewell with the experimental results.
Rocznik
Strony
297--302
Opis fizyczny
Bibliogr. 29 poz., il. kolor., fot., wykr.
Twórcy
  • Department of Mechanical Engineering, Amrita University, Coimbatore, India
  • Department of Mechanical Engineering, Amrita University, Coimbatore, India
  • Department of Mechanical Engineering, Amrita University, Coimbatore, India
  • Department of Mechanical Engineering, Amrita University, Coimbatore, India
Bibliografia
  • [1] D’Mello, G., Pai, P. S., Puneet, N. P. and Fang, N.: Surface roughness evaluation using cutting vibrations in high speed turning of Ti-6Al-4V - an experimental approach, International Journal of Machining and Machinability of Materials, vol. 18, pp. 288-312, 2016.
  • [2] Fang, N., Pai, P. S. and Mosquea, S.: Effect of tool edge wear on the cutting forces and vibrations in high-speed finish machining of Inconel 718: an experimental study and wavelet transform analysis, The International Journal of Advanced Manufacturing Technology, vol. 52, pp. 65-77, 2010.
  • [3] Krishnakumar, P., Prakash Marimuthu, K., Rameshkumar, K. and Ramachandran, K. I.: Finite element simulation of effect of residual stresses during orthogonal machining using ALE approach, Int. J. Machining and Machinability of Materials, vol. 14, pp. 213- 219, 2013-2014 2013.
  • [4] Thepsonthi, T. and Özel, T.: 3-D finite element process simulation of micro-end milling Ti-6Al-4V titanium alloy: Experimental validations on chip flow and tool wear, Journal of Materials Processing Technology, vol. 221, pp. 128-145, 2015.
  • [5] Bharathwaj, R., Giridharan, P., Karthick, K., Prasath, C. H. and Prakash Marimuthu, K.: Computational study of Coanda based Fluidic Thrust Vectoring system for optimising Coanda geometry, IOP Conference Series: Materials Science and Engineering, vol. 149, p. 012210, 2016-2017 2016.
  • [6] Kumar, B. V. R. M., Hemachandra Reddy, K. and Vikram Kumar, C. R.: Finite Element Model Based On Abaqus / Explicit To Analyze The Temperature Effects Of Turning, International Journal of Applied Engineering Research, vol. 11, pp. 5728-5734, 2016.
  • [7] Meyappan, P. L., Akhila Roy, Abhijith, J., Ramesh, M. N. V. and Prakash Marimuthu, K.: Tsunami Wave Impact on Structures, International Journal of Applied Engineering Research, vol. 10, pp. 1135-1139, 2014-2015 2015.
  • [8] Salahshoor, M. and Guo, Y. B.: Finite Element Simulation and Experimental Validation of Residual Stresses in High Speed Dry Milling of Biodegradable Mg-Ca Alloys, Procedia CIRP, vol. 14, pp. 281-286, 2014.
  • [9] Scippa, A., Grossi, N. and Campatelli, G.: FEM based Cutting Velocity Selection for Thin Walled Part Machining, Procedia CIRP, vol. 14, pp. 287-292, 2014.
  • [10] Boob, G. R., Deoghare, A. B.,Walke, P. V. and Padole, P. M.: Numerical modelling and simulation of orthogonal machining process using FE-code, International Journal of Machining and Machinability of Materials, vol. 17, pp. 370-380, 2015.
  • [11] Chen, L., El-Wardany, T. I. and Harris, W. C.: Modelling the Effects of Flank Wear Land and Chip Formation on Residual Stresses, CIRP Annals - Manufacturing Technology, vol. 53, pp. 95-98, 2004.
  • [12] Das, S. R., Dhupal, D. and Kumar, A.: Experimental investigation on cutting force and surface roughness inmachining of hardened aisi 52100 steel using cbn tool, 5th International & 26th All India Manufacturing Technology, Design and Research Conference (AIMTDR 2014) December 12th-14th, 2014, IIT Guwahati, Assam, India, 2014.
  • [13] Lu, J., Chen, J., Fang, Q., Liu, B., Liu, Y. and Jin, T.: Finite element simulation for Ti-6Al-4V alloy deformation near the exit of orthogonal cutting, The International Journal of Advanced Manufacturing Technology, vol. 85, pp. 2377-2388, 2015.
  • [14] Salvatore, F., Saad, S. and Hamdi, H.: Modeling and Simulation of Tool Wear During the Cutting Process, Procedia CIRP, vol. 8, pp. 305-310, 2013.
  • [15] Xi, Y., Bermingham, M., Wang, G. and Dargusch, M.: Finite Element Modeling of Cutting Force and Chip Formation During Thermally Assisted Machining of Ti6Al4V Alloy, Journal of Manufacturing Science and Engineering, vol. 135, p. 061014, 2013.
  • [16] Kailasam, R., Yuvaperiyasamy, M., Premkumar, R. and Dhanabal, M.: FEA of Chrome{Nickel Composite in Engine Valve Guides, Mechanics and Mechanical Engineering, vol. 21, pp. 5-10, 2017.
  • [17] Lykhachova, O.: Numerical Simulation of Axially Compressed Cylindrical Shells with Circular Cutouts, Mechanics and Mechanical Engineering, vol. 20, pp. 309-321, 2016.
  • [18] Marichamy, S., Saravanan, M., Ravichandran, M. and Stalin, B.: Optimization of Surface Roughness for Duplex Brass Alloy in EDM Using Response Surface Methodology, Mechanics and Mechanical Engineering, vol. 21, pp. 57-66, 2017.
  • [19] Selvaraj, J., Prakash Marimuthu, K., Devanathan, S. and Ramachandran, K. I.: Mathematical modelling of raw material preheating by energy recycling method in metal casting process, Pollution Research, vol. 36, pp. 217-228, 2017.
  • [20] Shanmughasundaram, P.: Effect of Temperature, Load and Sliding Velocity on the Wear Behavior of AA7075-SIC Composites, Mechanics and Mechanical Engineering, vol. 21, pp. 85-93, 2016.
  • [21] Sharma, R., Jadon, V. K. and Singh, B.: Thermo Mechanical Deformation and Stress Analysis of Hydroxyapatite/Titanium FGM plate by FEM, Mechanics and Mechanical Engineering, vol. 20, pp. 499-513, 2017.
  • [22] Kartik, B., Abishek, R., Kaliyannan, D. and Prakash Marimuthu, K.: Numerical Simulation of Low Velocity Impact Analysis of Fibre Metal Laminates, Mechanics and Mechanical Engineering, vol. 20, pp. 515-530, 2016.
  • [23] Milani, A. S., Dabboussi, W., Nemes, J. A. and Abeyaratne, R. C.: An improved multi-objective identification of Johnson-Cook material parameters, International Journal of Impact Engineering, vol. 36, pp. 294-302, 2// 2009.
  • [24] Pramod, M., Reddy, Y. G. and Prakash Marimuthu, K.: Prediction ofmachining induced residual stresses, AIP Conference Proceedings, vol. 1859, 2017.
  • [25] Nasr, M. N. A.: Effects of Sequential Cuts on Residual Stresses when Orthogonal Cutting Steel AISI 1045, Procedia CIRP, vol. 31, pp. 118-123, 2015.
  • [26] Valiorgue, F., Rech, J., Hamdi, H., Gilles, P. and Bergheau, J. M.: A new approach for the modelling of residual stresses induced by turning of 316L, Journal of Materials Processing Technology, vol. 191, pp. 270-273, 2007.
  • [27] Movahhedy, M. R., Gadala, M. S. and Altintas, Y.: Simulation of Chip Formation in Orthogonal Metal Cutting Process: An Ale Finite Element Approach, Machining Science and Technology, vol. 4, pp. 15-42, 2000.
  • [28] Prakash Marimuthu, K., Thirtha Prasada, H. P. and Chethan Kumar, C. S.: Force, Stress prediction in drilling of AISI 1045 steel using Finite Element Modelling, IOP Conf. Ser.: Mater. Sci. Eng, vol. 225, 012030, 2017.
  • [29] Prakash Marimuthu, K., Thirtha Prasada, H. P. and Chethan Kumar, C. S.: 3d Finite Element Model To PredictMachining Induced Residual Stresses Using Arbitrary Lagrangian Eulerian Approach, Journal of Engineering Science and Technology, in press.
Typ dokumentu
Bibliografia
Identyfikator YADDA
bwmeta1.element.baztech-0cb056a7-229a-4dec-b8ea-34f8da752a4d
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