A realistic 3D finite element model for simulating multiple rotations of modified milling inserts using coupled temperature-displacement analysis

Muaz, Muhammed; Choudhury, S.K.

doi:10.1007/s00170-020-05085-4

Cited by 10 publications

(4 citation statements)

References 33 publications

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“…In Abaqus, only m and t max are to be defined, which will be used by the model to determine the sliding and sticking regions. 39 Based on the previous studies, 23,39 the coefficient of friction (m) and maximum shear stress (t max ) selected for the model were 0.3 and 450 MPa, respectively.…”

Section: Constitutive Materials Behaviormentioning

confidence: 99%

“…The method of modification in the input file was well described in the author's previous work. 23 A reference point was taken on the insert and then it was defined isothermal using the point. Two different constraints, the kinematic coupling constraints and the beam-type MPC constraints were assigned to both of the inserts individually.…”

Section: Contact Constraints and Boundary Conditionsmentioning

confidence: 99%

“…Therefore, the experimental measurements were performed at the end of the slot just at the time when the tool left the machined surface. 23 Average values of the temperature for simulation and experimentation were compared. Prediction error for the temperature of the machined surface was found to be only 6.36%.…”

Section: Forces and Temperature During Cuttingmentioning

confidence: 99%

“…The prediction errors for the forces were less than 8.5%. Muaz and Choudhury 23 developed a 3D FEM for slot cutting operation through modified flat end milling inserts and experimentally validated with small prediction errors. The authors of all the works discussed so far did not perform a failure analysis of the process.…”

Section: Introductionmentioning

confidence: 99%

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Failure mechanics analysis of AISI 4340 steel using finite element modeling of the milling process

Muaz

Khan

2021

The Journal of Strain Analysis for Engineering Design

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A slot cutting operation is studied in this paper using a rotating/translating flat end milling insert. Milling operation usually comprises up-milling and down-milling processes. These two types of processes have different behaviors with opposite trends of the forces thus making the operation complex in nature. A detailed Finite Element (FE) model is proposed in this paper for the failure analysis of milling operation by incorporating damage initiation criterion followed by damage evolution mechanism. The FE model was validated with experimental results and good correlations were found between the two. The failure criteria field variable (JCCRT) was traced on the workpiece to observe the amount and rate of cutting during the machining process. It was found that the model was able to predict different failure energies that are dissipated during the machining operation which are finally shown to be balanced. It was also shown that the variation of these energies with the tool rotation angle was following the actual physical phenomenon that occurred during the cutting operation. Among all the energies, plastic dissipation energy was found to be the major contributor to the total energy of the system. A progressive failure analysis was further carried out to observe the nature of failure and the variation of stress components and temperature occurring during the machining process. The model proposed in this study will be useful for designers and engineers to plan their troubleshooting in various applications involving on-spot machining.

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Section: Constitutive Materials Behaviormentioning

confidence: 99%

Section: Contact Constraints and Boundary Conditionsmentioning

confidence: 99%

Section: Forces and Temperature During Cuttingmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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