CAD-Based Automated Design of FEA-Ready Cutting Tools

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

doi:10.3390/jmmp4040104

Cited by 14 publications

(10 citation statements)

References 28 publications

(34 reference statements)

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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: 87%

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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: 87%

“…In addition, Figure 1 depicts the feed direction. Finally, the models of the cutting tools were designed with the aid of an application developed by the authors [11] that is used to automatically generate FEA-ready turning insert models.…”

Section: Turning Process Frameworkmentioning

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

Self Cite

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“…A designer application [38] was used to generate the CAD model of the tool, including the full geometry. In contrast, the workpiece model was designed with SolidWorks™ 2018 based on the used depth of cut, the tool nose radius, and the steel bar diameter.…”

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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“…The tool-holder and the cutting tool were assembled so that the cutting angles can be derived. Moreover, the tool model was built via a developed application [9] that is used to automatically generate tool models of high quality. The used components have ISO designation numbers PCBNR2525M12 and CNGA120408 respectively.…”

Section: Setup Of the Machining Processmentioning

confidence: 99%

FEM-based investigation on machining forces and temperatures induced during AISI-4140 hard turning

Tzotzis

Efkolidis

Tzetzis

et al. 2022

IOP Conf. Ser.: Mater. Sci. Eng.

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Turning is probably one of the most common machining processes used to manufacture parts for the industrial sector. In order to reduce development times and costs during turning, it is necessary to employ methodologies and techniques that enable the precise prediction of the important parameters that relate to the process. Such a methodology is the implementation of Finite Element Method (FEM). In this work, the 3D modelling of AISI-4140 hard turning with ceramic tooling is being presented by utilizing the DEFORM-3D™ Finite Element Analysis (FEA) software system. Nine tests were conducted according to typical cutting conditions as recommended by tool manufacturers; cutting speed of 80 m/min, 115 m/min and 150 m/min and feed of 0.08 mm/rev, 0.11 mm/rev and 0.14 mm/rev, at a constant depth of cut equal to 0.30 mm. The developed friction forces, heat transfer and contact interface stresses between the tool and the workpiece were approximated with the aid of well-established models to simulate the machining mechanisms. Additionally, a validation of the yielded results for the machining components and the temperature distribution was performed by comparing the numerical results with experimental data. Most of the simulations generated results in agreement with the experimental ones. The agreement percentage exceeds 90% in most tests for the investigated components (machining forces and temperature), confirming both the validity and the accuracy of the model.

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CAD-Based Automated Design of FEA-Ready Cutting Tools

Cited by 14 publications

References 28 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

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

FEM-based investigation on machining forces and temperatures induced during AISI-4140 hard turning

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