Finite Element Analysis and Statistical Optimization of End-Burr in Turning AA2024

Abstract

This contribution presents three-dimensional turning operation simulations exploiting the capabilities of finite element (FE) based software Abaqus/Explicit. Coupled temperature-displacement simulations for orthogonal cutting on an aerospace grade aluminum alloy AA2024-T351 with the conceived numerical model have been performed. Numerically computed results of cutting forces have been substantiated with the experimental data. Research work aims to contribute in comprehension of the end-burr formation process in orthogonal cutting. Multi-physical phenomena like crack propagation, evolution of shear zones (positive and negative), pivot-point appearance, thermal softening, etc., effecting burr formation for varying cutting parameters have been highlighted. Additionally, quantitative predictions of end burr lengths with foot type chip formation on the exit edge of the machined workpiece for various cutting parameters including cutting speed, feed rate, and tool rake angles have been made. Onwards, to investigate the influence of each cutting parameter on burr lengths and to find optimum values of cutting parameters statistical analyses using Taguchi’s design of experiment (DOE) technique and response surface methodology (RSM) have been performed. Investigations show that feed has a major impact, while cutting speed has the least impact in burr formation. Furthermore, it has been found that the early appearance of the pivot-point on the exit edge of the workpiece surface results in larger end-burr lengths. Results of statistical analyses have been successfully correlated with experimental findings in published literature.

Effects of Adiabatic Heating and Strain Rate on the Dynamic Response of a CoCrFeMnNi High-Entropy Alloy

“…In their initial investigations on copper samples, the authors established that the fraction of plastic work converted to heat during plastic deformation was of approximately 0.9. Although it has already been established that β depends on strain, strain rate, and loading mode [12], the assumption of a constant β value of 0.9 for different metallic materials is still common in the recent literature [6,[15][16][17][18][19].…”

Effects of Tool Edge Geometry on Chip Segmentation and Exit Burr: A Finite Element Approach

“…Fisher Coe f f icient(F-value) = MS i MS Error (17) Percent Contributi on : In the ANOVA table, significance or insignificance is attributed to each of the source factors based on the Fisher coefficient value (F-value). ANOVA for significance level = 5% (95% confidence level) was performed.…”

“…This ultimately will help to increase tool life and improve surface integrity. Furthermore, physical comprehension of burr formation mechanisms and burr control through parametric optimization and tool and workpiece geometry optimization have also been widely discussed in literature [3,4,6,7,[17][18][19].…”

Significant Contribution of Temperature on AISI D2 Tool Steel Ground Surface Characteristics and Integrities

“…Consequently, this results in gradient surfaces with microstructural and mechanical properties that can compromise the life integrity of the finished or machined workpiece [7][8][9]. Several studies have been devoted to the identification of these interactions and their quantitative evaluation using experimental approaches [10][11][12], analytical models [6,13,14] and numerical simulations [14][15][16][17]. The resolution of this problematic requires the development of an experimental and / or a numerical evaluation methodology.…”