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

Kyratsis, Panagiotis; Tzotzis, Anastasios; Markopoulos, Angelos P.; Tapoglou, Nikolaos

doi:10.3390/machines9010004

Cited by 21 publications

(9 citation statements)

References 47 publications

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“…In order to be able to examine the validity of the models, a comparison was made with results from the bibliography. Similar studies for hard turning of AISI-4140 [6,7,11] and AISI-D3 [8] with the use of ceramic inserts, at similar cutting conditions, present results for the cutting forces, which are of the same magnitude with the results of the present study.…”

Section: Resultssupporting

confidence: 88%

“…Authors processed the obtained results with well-established mathematical methodologies in order to develop prediction models. Kyratsis et al [8] employed similar strategies to study the machining of AISI-D3 tool steel and examine the effects of typical cutting conditions on the generated cutting forces for prediction purposes. Moreover, authors analyzed the development of the cutting forces on a wide range of cutting conditions.…”

Section: Introductionmentioning

confidence: 99%

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FEM-based comparative study of SQUARE & RHOMBIC INSERT machining performance during turning of AISI-D3 steel

Tzotzis¹,

Efkolidis²,

Oancea³

et al. 2021

IJMMT

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Nowadays, employment of the Finite Element Method (FEM) in machining simulation is a common practice to decrease development times and costs, as well as to investigate numerous parameters that affect machining processes. In the present work, the 3D modelling of AISI-D3 hard turning with both square and rhombic inserts is being presented by utilizing a commercially available Finite Element Analysis (FEA) software. Eighteen tests were carried out based on cutting conditions that are recommended for the used tools. Specifically, three levels of cutting speed (75m/min, 110m/min and 140m/min), three levels of feed (0.12mm/rev, 0.16mm/rev and 0.20mm/rev) and depth of cut equal to 0.40mm for all tests, were applied. In order to describe the complex factors that define the model, such as the friction forces, the heat transfer and the pressure due to contact between the tool and the workpiece, a number of acknowledged models were utilized. A comparison of the performance between the two types of tools was made with respect to the developed machining forces and temperature distribution on the workpiece. The findings of the investigation indicate that the specific square tools produce higher values of forces compared to the rhombic ones and approximately the same temperature patterns on the workpiece. The average increase on the produced cutting forces is about 26.4%.

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Section: Resultssupporting

confidence: 88%

Section: Introductionmentioning

confidence: 99%

FEM-based comparative study of SQUARE & RHOMBIC INSERT machining performance during turning of AISI-D3 steel

Tzotzis¹,

Efkolidis²,

Oancea³

et al. 2021

IJMMT

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“…Taguchi's approach introduces a design methodology for reduced labor costs with increased efficiency [47][48][49]. Its main purpose is quality engineering.…”

Section: Taguchi's S/n Ratio Methodsmentioning

confidence: 99%

Parametric Optimization for Cutting Forces and Material Removal Rate in the Turning of AISI 5140

et al. 2021

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The present paper deals with the optimization of the three components of cutting forces and the Material Removal Rate (MRR) in the turning of AISI 5140 steel. The Harmonic Artificial Bee Colony Algorithm (H-ABC), which is an improved nature-inspired method, was compared with the Harmonic Bee Algorithm (HBA) and popular methods such as Taguchi’s S/N ratio and the Response Surface Methodology (RSM) in order to achieve the optimum parameters in machining applications. The experiments were performed under dry cutting conditions using three cutting speeds, three feed rates, and two depths of cuts. Quadratic regression equations were identified as the objective function for HBA to represent the relationship between the cutting parameters and responses, i.e., the cutting forces and MRR. According to the results, the RSM (72.1%) and H-ABC (64%) algorithms provide better composite desirability compared to the other techniques, namely Taguchi (43.4%) and HBA (47.2%). While the optimum parameters found by the H-ABC algorithm are better when considering cutting forces, RSM has a higher success rate for MRR. It is worth remarking that H-ABC provides an effective solution in comparison with the frequently used methods, which is promising for the optimization of the parameters in the turning of new-generation materials in the industry. There is a contradictory situation in maximizing the MRR and minimizing the cutting power simultaneously, because the affecting parameters have a reverse effect on these two response parameters. Comparing different types of methods provides a perspective in the selection of the optimum parameter design for industrial applications of the turning processes. This study stands as the first paper representing the comparative optimization approach for cutting forces and MRR.

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“…A large amount of research has been undertaken in the area, resulting in efficient ways of simulating and predicting in cut characteristics. In the area of simulation of manufacturing processes, a series of approaches have been presented by researchers including analytical-, simulation-and experimentalbased models [6][7][8][9][10][11][12][13][14][15]. The most common simulation models include finite element and mathematical models.…”

Section: State Of the Artmentioning

confidence: 99%

Development of Cutting Force Model and Process Maps for Power Skiving Using CAD-Based Modelling

Tapoglou

2021

Machines

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Power skiving is a new gear cutting process that has been recognized to provide a step change in the production rate achieved in the machining of high-precision internal and external involute gears. The process is based on a continuous generating meshing between the workgear and the cutting tool. Understanding of the loads applied in the cutting tool, and therefore some of the sources of tool wear, have not been thoroughly understood. This paper presents a novel model that is able to predict with high accuracy the cutting forces in the power skiving process. The model is based on a solid modelling simulation algorithm that produces high-fidelity solid bodies that are used for the calculations. The results of the model have been experimentally validated. A series of process maps are also produced to assist in the identification of the optimal machining parameters.

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

Cited by 21 publications

References 47 publications

FEM-based comparative study of SQUARE & RHOMBIC INSERT machining performance during turning of AISI-D3 steel

FEM-based comparative study of SQUARE & RHOMBIC INSERT machining performance during turning of AISI-D3 steel

Parametric Optimization for Cutting Forces and Material Removal Rate in the Turning of AISI 5140

Development of Cutting Force Model and Process Maps for Power Skiving Using CAD-Based Modelling

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