PL EN


Preferencje help
Widoczny [Schowaj] Abstrakt
Liczba wyników
Tytuł artykułu

Finite element analysis of influence of flank wear evolution on forces in orthogonal cutting of 42CrMo4 steel

Treść / Zawartość
Identyfikatory
Warianty tytułu
Języki publikacji
EN
Abstrakty
EN
This paper presents analysis of flank wear influence on forces in orthogonal turning of 42CrMo4 steel and evaluates capacity of finite element model to provide such force values. Data about magnitude of feed and cutting force were obtained from measurements with force tensiometer in experimental test as well as from finite element analysis of chip formation process in ABAQUS/Explicit software. For studies an insert with complex rake face was selected and flank wear was simulated by grinding operation on its flank face. The aim of grinding inset surface was to obtain even flat wear along cutting edge, which after the measurement could be modeled with CAD program and applied in FE analysis for selected range of wear width. By comparing both sets of force values as function of flank wear in given cutting conditions FEA model was validated and it was established that it can be applied to analyze other physical aspects of machining. Force analysis found that progression of wear causes increase in cutting force magnitude and steep boost to feed force magnitude. Analysis of Fc/Ff force ratio revealed that flank wear has significant impact on resultant force in orthogonal cutting and magnitude of this force components in cutting and feed direction. Surge in force values can result in transfer of substantial loads to machine-tool interface.
Rocznik
Tom
Strony
58--64
Opis fizyczny
Bibliogr. 29 poz., fig., tab.
Twórcy
  • Poznan University of Technology, Piotrowo 3 Street, 60-965 Poznan, Poland
  • Poznan University of Technology, Piotrowo 3 Street, 60-965 Poznan, Poland
Bibliografia
  • [1] Merchant M.E., Mechanics of the metal cutting process. I. Orthogonal cutting and a type 2 chip, Journal of Applied Physics, 16 (1945).
  • [2] Oxley P.L.B., Mechanics of machining: an analytical approach to assessing machinability. New York: Wiley, 1989.
  • [3] Alcaraz J.L, Lorenzo I., Thermomechanical Analysis of a Chip Machining Process, ABAQUS Users’ Conference, Munich, Germany, (2003).
  • [4] Cai Y.J., Dou T., Duan C.Z., Li, Y., Finite Element Simulation and Experiment of Chip Formation Process during High Speed Machining of AISI 1045 Hardened Steel, International Journal of Recent Trends in Engineering, 5 (2009).
  • [5] Díaz J., Miguélez H., Surface integrity in finishing turning of Inconel 718, Proceedings of the 5th Manufacturing Engineering Society International Conference, Saragossa, Spain, (2013).
  • [6] Mashayekhi M., Salimi M., Vaziri M.R., Evaluation of Chip Formation Simulation Models for Material Separation in the Presence of Damage Models, Simulation Modeling Practice and Theory, 19 (2011), 718-733.
  • [7] Pantale O., 2D and 3D numerical models of metal cutting with damage effects, Computer Methods In Applied Mechanics And Engineering, 193 (2004), 4383-4399.
  • [8] Awang M.B., Hairudin M., Thermo mechanical Modeling of Turning Process using an Arbitrary Lagrangian-Eulerian Method, National Postgraduate Conference (NPC), Tanjung Tokong, Malaysia, (2011).
  • [9] Özel T., Zeren E., Finite Element Method Simulation of Machining of AISI 1045 Steel With A Round Edge Cutting Tool, Proc. 8th CIRP Int. Workshop on Modeling of Machining Operations, Chemnitz, Germany, (2005), 533-541.
  • [10] Razfar M.R., Sadeghinia H., Takabi J., Simulation of Orthogonal Cutting Process Using Arbitrary Lagrangian-Eulerian Approach, 3rd WSEAS International Conference On Applied And Theoretical Mechanics, Tenerife, Spain, (2007).
  • [11] Arrazola P.J., Meslin F., Hammann J.C., Maitre F., Numerical Cutting Modeling with Abaqus/Explicit 6.1, ABAQUS Users' Conference Newport, Rhode Island, USA, (2002).
  • [12] Fleisher J., Schermann T., Aspects of the simulation of a cutting process with ABAQUS/Explicit including the interaction between the cutting process and the dynamic behavior of the machine tool, 9th CIRP International Workshop on Modeling of Machining Operations, Bled, Slovenia, (2006).
  • [13] Pantale O., An ALE Three-dimensional Model of Orthogonal and Oblique Metal Cutting Processes, International Journal of Forming Processes, 9 (1998), 371-388.
  • [14] Usui E., Kitagawwa T., Maekawa K., Shirakashi T., Analytical Prediction of Flank Wear of Carbide Tools in Turning Plain Carbon Steels, Bull. Japan Soc. of Prec. Eng., 23 (1989), 263-269.
  • [15] Xie L.J., Schmidt J., Schmidt C., Biesinger F., 2D FEM Estimate of Tool Wear in Turning Operations, WEAR ELSEVIER, 258 (2005), 1479-1490.
  • [16] Yen Y.C., Sohner J., Lilly B., Altan T., Estimation of Tool Wear of Carbide Tool in Orthogonal Cutting Using FEM Simulation, Machining Science and Technology, 6 (2002), 467-486.
  • [17] Yue C.X., Liu X.L., Pen H.M., Hu J.S., Zhao X.F., 2D FEM Estimate of Tool Wear in Hard Cutting Operation: Extractive of Interrelated Parameters and Tool Wear Simulation Result, Advanced Materials Research, 69 (2009), 316-321.
  • [18] Koren Y., Ko T.R., A Comprehensive Wear Model For Cutting Tools, Technical Raport No. UM-MEAM-88-5 (1988).
  • [19] Docobu F., Arrazola P.J., Riviere-Lorphevre E., Filippi E., Finite element prediction of the tool wear influence inTi6Al4V machining, 15th CIRP Conference on Modeling of Machining Operations, Karlsruhe, Germany, (2015)
  • [20] Kohir V., Dundur S.T., Finite Element Simulation to study the effect of flank wear land inclination on Cutting forces and temperature distribution in orthogonal machining, Journal of Engineering and Fundamentals, 1 (2014), 30-42.
  • [21] Chen L., El-Wardany T.I., Harris W.C., Modeling the Effects of Flank Wear Land and Chip Formation on Residual Stresses, CIRP Annals - Manufacturing Technology, 53 (2004), 95-98.
  • [22] Dubiec J., Neslusan M., Micietova A., Cillikova M., Influence of Flank Wear on Decomposition of Cutting Forces in Turning, MM Science Journal, 17 (2013).
  • [23] DASSAULT SYSTÈMES, Abaqus Analysis User's Manual, available at: http://www.tu-chemnitz.de/projekt/abq_hilfe/docs/v6.12/.
  • [24] Zorev N.N., Inter-relationship between shear processes occurring along tool face and shear plane in metal cutting, International Research In Production Engineering, (1963), 42-49.
  • [25] Ai Y.J., Dou T., Duan C.Z., Li, Y., Finite Element Simulation and Experiment of Chip Formation Process during High Speed Machining of AISI 1045 Hardened Steel, International Journal of Recent Trends in Engineering, 5 (2009).
  • [26] Bell T., Srivastava A.K., Zhang X., Investigations on turningTi-6Al-4V titanium alloy using super-finished tool edge geometry generated by micro-machining process (MMP), Penn State College of Engineering, (2011).
  • [27] Cook W.H., Johnson G.R., A constitutive model and data for metals subjected to large strains, high strain rates and high temperatures, Proceedings of the 7th International Symposium on Ballistics, Haga, Switzerland, (1983).
  • [28] Ulutan D., Özel T., Determination of tool friction in presence of flank wear and stress distribution based validation using finite element simulations in machining of titanium and nickel based alloys, Journal of Materials Processing Technology, 213 (2013).
  • [29] Özel T., The influence of friction models on finite element simulations of machining, International Journal of Machine Tools & Manufacture, 46 (2006).
Uwagi
Opracowanie ze środków MNiSW w ramach umowy 812/P-DUN/2016 na działalność upowszechniającą naukę (zadania 2017).
Typ dokumentu
Bibliografia
Identyfikator YADDA
bwmeta1.element.baztech-cc4cefc2-fa94-4d69-b5ab-d81e8ff17170
JavaScript jest wyłączony w Twojej przeglądarce internetowej. Włącz go, a następnie odśwież stronę, aby móc w pełni z niej korzystać.