3D FE Modelling of Machining Forces during AISI 4140 Hard Turning

Tzotzis, Anastasios; García-Hernández, César; Talón, José Luís Huertas; Kyratsis, Panagiotis

doi:10.5545/sv-jme.2020.6784

Cited by 16 publications

(13 citation statements)

References 25 publications

(32 reference statements)

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“…At the pre-processing stage, the workpiece was modelled as deformable and meshed with approximately 32,000 to 60,000 tetrahedral elements depending on the value of the feed. The minimum element size of the mesh was set to 25% of the feed [39,40]. Moreover, a 7:1 ratio between the largest and the smallest element size of the mesh was applied to the section of the workpiece (see Figure 2b), so that the solid elements of the workpiece that participate in the removal process are created seven times smaller compared to the rest of the elements.…”

Section: Definition Of the Analysis Interfacementioning

confidence: 99%

CAD-Based 3D-FE Modelling of AISI-D3 Turning with Ceramic Tooling

et al. 2021

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In this study, the development of a 3D Finite Element (FE) model for the turning of AISI-D3 with ceramic tooling is presented, with respect to four levels of cutting speed, feed, and depth of cut. The Taguchi method was employed in order to create the orthogonal array according to the variables involved in the study, reducing this way the number of the required simulation runs. Moreover, the possibility of developing a prediction model based on well-established statistical tools such as the Response Surface Methodology (RSM) and the Analysis of Variance (ANOVA) was examined, in order to further investigate the relationship between the cutting speed, feed, and depth of cut, as well as their influence on the produced force components. The findings of this study point out an increased correlation between the experimental results and the simulated ones, with a relative error below 10% for most tests. Similarly, the values derived from the developed statistical model indicate a strong agreement with the equivalent numerical values due to the verified adequacy of the statistical model.

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Section: Definition Of the Analysis Interfacementioning

confidence: 99%

CAD-Based 3D-FE Modelling of AISI-D3 Turning with Ceramic Tooling

et al. 2021

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“…The models of the three turning inserts were designed according to the ISO-13399 norms (see Figure 3b), whereas the simplified version of the workpiece was designed with respect to the depth of cut, the nose radius of the tool and the diameter of the steel bar. Moreover, the workpiece was modeled as deformable (plastic) with a mesh that varied between 100,000 and 150,000 elements depending on the size of the minimum element, which was fixed to 25% of the feed value for all tests [29]. Since the area of interest is at the uncut surface of the workpiece, where contact between the insert and the workpiece exists, a finer mesh was applied with a 7:1 ratio (see Figure 4b).…”

Section: Configuration Of the Insert-workpiece Interfacementioning

confidence: 99%

Influence of the Nose Radius on the Machining Forces Induced during AISI-4140 Hard Turning: A CAD-Based and 3D FEM Approach

et al. 2020

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The present study investigated the performance of three ceramic inserts in terms of the micro-geometry (nose radius and cutting edge type) with the aid of a 3D finite element (FE) model. A set of nine simulation runs was performed according to three levels of cutting speed and feed rate with respect to a predefined depth of cut and tool nose radius. The yielded results were compared to the experimental values that were acquired at identical cutting conditions as the simulated ones for verification purposes. Consequently, two more sets of nine simulations each were carried out so that a total of 27 turning simulation runs would adduce. The two extra sets corresponded to the same cutting conditions, but to different cutting tools (with varied nose radius). Moreover, a prediction model was established based on statistical methodologies such as the response surface methodology (RSM) and the analysis of variance (ANOVA), further investigating the relationship between the critical parameters (cutting speed, feed rate, and nose radius) and their influence on the generated turning force components. The comparison between the experimental values of the cutting force components and the simulated ones demonstrated an increased correlation that exceeded 89%. Similarly, the values derived from the statistical model were in compliance with the equivalent FE model values due to the verified adequacy.

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“…On the other hand, the mesh size of the workpiece varied according to the value of feed. The size of the minimum element was fixed to 25% of the feed for all tests [33]. Additionally, the selected workpiece material is AISI-4140 steel.…”

Section: Testing Of the Generated Cutting Tool Modelsmentioning

confidence: 99%

“…An effort was made to keep it as simplified as possible. Additionally, to better approximate the contact interface between the tool and the workpiece, the mesh on the tool was refined locally at the cutting tip by applying a ratio of 4:1 [33], as illustrated in Figure 8c. The velocity of the nodes in X and Z axis was set to zero by fixing the workpiece, as shown in Figure 8a.…”

Section: J Manuf Mater Process 2020 4 X For Peer Review 11 Of 15mentioning

confidence: 99%

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CAD-Based Automated Design of FEA-Ready Cutting Tools

Tzotzis

García-Hernández

Talón

et al. 2020

JMMP

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The resources of modern Finite Element Analysis (FEA) software provide engineers with powerful mechanisms that can be used to investigate numerous machining processes with satisfying results. Nevertheless, the success of a simulation, especially in three dimensions, relies heavily on the accuracy of the cutting tool models that are implemented in the analyses. With this in mind, the present paper presents an application developed via Computer-Aided Design (CAD) programming that enables the automated design of accurate cutting tool models that can be used in 3D turning simulations. The presented application was developed with the aid of the programming resources of a commercially available CAD system. Moreover, the parametric design methodology was employed in order to design the tools according to the appropriate standards. Concluding, a sample tool model was tested by performing a number of machining simulations based on typical cutting parameters. The yielded results were then compared to experimental values of the generated machining force components for validation. The findings of the study prove the functionality of the tool models since a high level of agreement occurred between the acquired numerical results and the experimental ones.

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3D FE Modelling of Machining Forces during AISI 4140 Hard Turning

Cited by 16 publications

References 25 publications

CAD-Based 3D-FE Modelling of AISI-D3 Turning with Ceramic Tooling

CAD-Based 3D-FE Modelling of AISI-D3 Turning with Ceramic Tooling

Influence of the Nose Radius on the Machining Forces Induced during AISI-4140 Hard Turning: A CAD-Based and 3D FEM Approach

CAD-Based Automated Design of FEA-Ready Cutting Tools

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