Experimental and numerical analysis of hard turning with multi-chamfered cutting edges

Magalhães, Frederico C.; Ventura, Carlos Eiji Hirata; Abrão, Alexandre Mendes; Denkena, Berend

doi:10.1016/j.jmapro.2019.11.025

Cited by 29 publications

(13 citation statements)

References 22 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…Buchkremer et al [30] proposed a new model of final ductile fracture for the 3D-FE simulation of chip breakage in the turning process of AISI-1045, along with a new non-iterative calibration procedure. Magalhães et al [31] established a FE model for hard turning examining the effects of multi-chamfered edges on tool wear and residual stresses. Tzotzis et al [32] investigated the performance of ceramic inserts in terms of the micro-geometry (nose radius and cutting edge type) with the aid of 3D-FE modelling.…”

Section: Introductionmentioning

confidence: 99%

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

et al. 2021

View full text Add to dashboard Cite

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.

show abstract

Section: Introductionmentioning

confidence: 99%

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

et al. 2021

View full text Add to dashboard Cite

show abstract

“…Hu and Huang [ 22 ] examined the effects of cutting speed on the turning force, the temperature distribution, and the tool wear during turning of AISI-4130 with ceramic tools based on 3D FEM. Magalhães et al [ 23 ] presented a finite element (FE) model for hard turning with PCBN inserts prepared with multi-chamfered edges and examined the effects on tool wear and residual stresses.…”

Section: Introductionmentioning

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

View full text Add to dashboard Cite

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.

show abstract

“…The proposed model was applied to AISI 1045 hard turning and was analysed via orthogonal experiments for different coating thickness, material, and ratios of the soft/hard coatings. Magalhães et al [22] aimed to provide a better understanding of the mechanical and thermal loads involved in cutting, with respect to the variation of the tool's edge discretization. To do so, they prepared numerical simulations of AISI 5115 steel hard turning using finite element analysis (FEA).…”

Section: Introductionmentioning

confidence: 99%

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

Tzotzis

García-Hernández

Talón

et al. 2020

SV-JME

View full text Add to dashboard Cite

Hard turning is one of the most used machining processes in industrial applications. This paper researches critical aspects that influence the machining process of AISI-4140 to develop a prediction model for the resultant machining force-induced during AISI-4140 hard turning, based on finite element (FE) modelling. A total of 27 turning simulation runs were carried out in order to investigate the relationship between three key parameters (cutting speed, feed rate, and depth of cut) and their effect on machining force components. The acquired numerical results were compared to experimental ones for verification purposes. Additionally, a mathematical model was established according to statistical methodologies such as the response surface methodology (RSM) and the analysis of variance (ANOVA). The plurality of the simulations yielded results in high conformity with the experimental values of the main machining force and its components. Specifically, the resultant cutting force agreement exceeded 90 % in many tests. Moreover, the verification of the adequacy of the statistical model led to an accuracy of 8.8 %.

show abstract

Experimental and numerical analysis of hard turning with multi-chamfered cutting edges

Cited by 29 publications

References 22 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

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

Contact Info

Product

Resources

About