On the turning modeling and simulation: 2D and 3D FEM approaches

Abstract

For qualitative prediction of chip morphology and quantitative prediction of burr size, 2D and 3D finite element (FE) based turning models have been developed in this paper. Coupled temperaturedisplacement machining simulations exploiting the capabilities of Abaqus r with a particular industrial turning insert and a newly proposed geometrical version of this insert have been performed. Limitations of 2D models in defining the chip morphologies and surface topologies have been discussed. The phenomenological findings on the Poisson burr (Side burr) formation using 3D cutting models have been highlighted. Bespoke geometry of the turning insert has been found helpful in reducing the Poisson burr formation, as it reduces the contact pressures at the edges of tool rake face-workpiece interface. Lower contact pressures serve to decrease the material flow towards workpiece edges (out of plane deformation). In contrast, higher contact pressures at tool rake face-workpiece interface lead to more material flow towards workpiece edges resulting in longer burr. Simulation results of chip morphologies and cutting forces for turning an aluminum alloy A2024-T351 have been compared with the experimental ones. Finally, it has been concluded that the newly proposed geometry of the insert not only decreases the burr but also helpful in lessening the magnitude of tool-workpiece initial impact.

Numerical modeling and simulation of macro- to microscale chip considering size effect for optimum milling characteristics of AA2024T351

“…It was analyzed that all the deformed chips show a maximum stress concentration at the chip edge tip and shear zone. This effect was also published by Asad et al [52] and Waqas et al [21]. The deviation of maximum von Mises stress for μ = 0.2 and μ = 0.3 is shown in Fig.…”

An advanced efficient model for adhesive wear in elastic—plastic spherical contact

“…where Aluminum 2024 T351 is selected for the sphere since the failure criteria for this particular material have already been studied by experiments [29][30][31] and are well documented in Refs. [32][33][34]. As in Ref.…”

Plasticity-induced damage and material loss in oscillatory contacts

“…Table 2 gives the material properties and the damage constants used in the FEM simulations. The mechanical properties given in Table 2 are typical of A2024-T351 aluminum alloy, which is widely used in aerospace, automotive, machining, and other industrial applications mainly due to its high strength, low weight, good machinability, and good fatigue resistance (Asad et al, 2014).…”