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2 Mechanics and Mechanical Engineering

2 2019

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Numerical validation of drilling of Al6061-T6 with experimental data

Elango Prashant, Marimuthu K. Prakash

Mechanics and Mechanical Engineering

2019

Vol. 23, nr 1

287--290

Drilling is a cutting process that uses a drill bit to cut a circular profile in workpiece. Forces acting on the drill bit reduce its life expectance. Analysis of forces acting on the drill bit during drilling prevents the tool from failing prematurely because of wear and excess feed rate. Excess feed rate can induce excessive internal stress on both the tool and workpiece. This paper aims to study the effects of reaction force acting on a drill bit during drilling of Al6061-T6. A numerical finite element simulation study is performed with commercially available software called Abaqus. Simulation results depend on the right choice of material property such as Johnson-Cook material property and Johnson-Cook damage property. Validation of material property is achieved by comparison of experimental results with simulative results. Reaction force acting against the drill bit during drilling is compared.

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

Venkatesh S. Sai, Ram Kumar T. A., Blalakumhren A. P., Saimurugan M., Marimuthu K. Prakash

Mechanics and Mechanical Engineering

2019

Vol. 23, nr 1

297--302

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.