FEM Simulation of the Residual Stress in the Machined Surface Layer for High-Speed Machining

Wang, Su Yu; Ai, Xing; Zhao, Jun; Lv, Zijian

doi:10.4028/www.scientific.net/kem.315-316.140

Cited by 4 publications

(3 citation statements)

References 2 publications

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“…Hence compressive to tensile transformation occurs at higher cutting speeds due to increased cutting temperature in case of high speed machining. It holds good only on the surface, but beneath the surface, variation of strains and rate of strain have to be taken into consideration due to its dominant role [12]. Apart from speed, feed and uncut chip thickness, nose radius, chamfer angle and rake angle influenced residual stress.…”

Section: Literature Reviewmentioning

confidence: 99%

Numerical Analysis of Surface Integrity in Parallel Turning Process Part II: Influence of Cutting Tool Rake Angle

Kalidasan

2022

KEM

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Parallel turning is one among the advanced unconventional turning process. It employs two turning tools operating concurrently to cut the material from the workpiece. For turned rotary components, surface integrity is a major quality indicator that determines the fatigue life of the finished workpiece. Tool parting distance, rake angle and edge radius affects surface integrity. Part I dealt with numerical analyses to determine the effect of parting distance on surface integrity using finite element based commercial software Abaqus 6.14. Here in Part II, the impact of rake angle over surface integrity for various cutting speeds and feeds are numerically analyzed. It was observed that with the rise in negative rake angle the negative residual stresses decreased for the machined surface of leading and lagging cutting tool. When the rake angle is increased from-10 ̊ to-2 ̊, percentage reduction of negative residual stresses is same for the turned surfaces of both tools. The cutting velocity was 250 m/min and feed 0.2 mm/rev. With the rise in rake angle, the friction angle reduced but shear angle raised. When the cutting velocity increased, the shear angle of the leading and lagging cutting tool reduced. Lower shear angle causes higher stagnation region which further causes higher compressive surface residual stress.

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Section: Literature Reviewmentioning

confidence: 99%

Numerical Analysis of Surface Integrity in Parallel Turning Process Part II: Influence of Cutting Tool Rake Angle

Kalidasan

2022

KEM

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“…El-Axir [44] calculates residual stress profiles based on the assumption that they are only dependent on initial tensile strength and the cutting parameters. Wang et al [45] developed an fe-based model for the simulation of residual stress profiles in high-speed machining, without experimental validation. Zhang et al [46] trained a neural network (nn) using experimental data.…”

Section: Introductionmentioning

confidence: 99%

Machine Learning of Surface Layer Property Prediction for Milling Operations

Uhlmann

Holznagel

Schehl

et al. 2021

JMMP

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Tool wear and cutting parameters have a significant effect on the surface layer properties in milling. Since the relation between tool wear, cutting parameters, and surface layer properties is mostly unknown, the latter cannot be controlled during production and may vary from part to part as tool wear progresses. To account for this uncertainty and to prevent premature failure, components often need to be oversized or surface layer properties need to be adjusted in subsequent manufacturing processes. Several approaches have been made to obtain models that predict the surface layer properties induced by manufacturing processes. However, those approaches need to be calibrated with a considerable number of experimental trials. As trials are time-consuming and surface layer measurements are laborious, no industrial applications have been realized. Complex models have one major drawback. They have to be re-parameterized as soon as process characteristics change. Therefore, manual experimental parameterization does not appear to be a feasible approach for industrial application. A highly automated approach for the machine learning of the relation between tool wear, cutting parameters and surface layer properties is presented in this paper. The amount of obtained measurement data allows a fundamental analysis of the approach, which paves the way for further developments.

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“…In recent years, the dynamic thermomechanical responses of workpiece materials with various cutting parameters have been effectively investigated by FE simulation. The residual stress in the machined surface layer for high-speed machining was analyzed in [1], and Hashish et al specially discussed the residual stress induced by high pressure waterjet peening [2]. The cutting force in high speed metal machining was simulated in [3] and Bhatnagar et al also studied the cutting force for composites machining [4].…”

Section: Introductionmentioning

confidence: 99%

FE Analysis of the Effects of Cutting Speed on Thermomechanical Responses of AISI 4142 Steel in High Speed Cutting

Gao

Fang

2010

AMR

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The high-speed metal cutting process is analyzed by finite element (FE) method in order to understand the effects of the cutting speed on the thermomechanical responses of workpiece materials. The reliability of numerical simulation is firstly validated by comparing the simulated cutting force with experimental data. Then a series of FE simulations are carried out to reveal the effects of the cutting speed on three key cutting state variables. The cutting force varies with the cutting speed and shows a minimum inflexion at 10 m/s. The maximum temperature in the secondary deformation zone increases gradually with the cutting speed and finally tends to a steady value. The residual stress decreases with the cutting speed as a whole. Thus high speed cutting can improve surface machining precision of product. Besides, it is found that the high residual stress mainly concentrates in the topmost surface layer with a depth of 0.1 mm and sharply decreases to a low level beyond the layer.

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FEM Simulation of the Residual Stress in the Machined Surface Layer for High-Speed Machining

Cited by 4 publications

References 2 publications

Numerical Analysis of Surface Integrity in Parallel Turning Process Part II: Influence of Cutting Tool Rake Angle

Numerical Analysis of Surface Integrity in Parallel Turning Process Part II: Influence of Cutting Tool Rake Angle

Machine Learning of Surface Layer Property Prediction for Milling Operations

FE Analysis of the Effects of Cutting Speed on Thermomechanical Responses of AISI 4142 Steel in High Speed Cutting

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