Thermal analysis during turning of AZ31 magnesium alloy under dry and cryogenic conditions

Danish, Mohd; Ginta, Turnad Lenggo; Habib, Khairul; Carou, Diego; Rani, Ahmad Majdi Abdul; Saha, Bidyut Baran

doi:10.1007/s00170-016-9893-5

Cited by 136 publications

(46 citation statements)

References 38 publications

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“…Direct measurement of such loads is often impossible, and therefore, in recent years, the finite element modelling technique has become an important numerical tool for simulating the machining process. Constitutive models describing the material flow behaviour as a function of strain hardening, strain rate hardening, and thermal softening are required in order to capture the plasticity behaviour of the workpiece, during the conditions encountered in the machining process [13,32]. In finite element simulations, there are two types of formulations, Eulerian and Lagrangian.…”

Section: Introductionmentioning

confidence: 99%

Development of a simulation model to study tool loads in pcBN when machining AISI 316L

Agmell

Bushlya

Laakso

et al. 2018

Int J Adv Manuf Technol

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This paper presents the development of a FE-simulation model to predict the mechanical stresses and thermal loads that a cutting tool of polycrystalline cubic boron nitride (pcBN) is subjected to, when machining AISI 316L. The serrated chip formation of AISI 316L has a major impact on the periodic loads acting on the cutting tool. Therefore, it is vital to correctly model this serrated chip formation. One of the major difficulties with FE-simulations of metal cutting is that the extreme deformations in the workpiece material, often leads to a highly distorted mesh. This paper uses the Coupled EulerianLagrangian (CEL) formulation in Abaqus/Explicit, where the workpiece is modelled with the Eulerian formulation and the cutting tool by the Lagrangian one. This CEL formulation enables to completely avoid mesh distortion. To capture the chip serration process, the workpiece material is described with the Johnson-Cook damage model. The FE-simulation results are validated via comparison of the modelled cutting forces, chip serration frequency, and contact length against experimental ones.

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Section: Introductionmentioning

confidence: 99%

Development of a simulation model to study tool loads in pcBN when machining AISI 316L

Agmell

Bushlya

Laakso

et al. 2018

Int J Adv Manuf Technol

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show abstract

“…This increases the total number of tests and as a result the experimentation cost also increases. Design and methods such as response surface methodology (RSM) [ 40 ] and Taguchi methods [ 41 ] are now widely used in place of a one-factor-at-a-time experimental approach which is time consuming and exorbitant in cost. RSM is a dynamic and foremost important tool of design of experiment (DOE), wherein the relationship between the output variables of a process with its input parameters (cutting conditions) is mapped to achieve the objective of maximization or minimization of the response properties.…”

Section: Introductionmentioning

confidence: 99%

Study on the Optimum Cutting Parameters of an Aluminum Mold for Effective Bonding Strength of a PDMS Microfluidic Device

Yousuff

Danish

et al. 2017

Micromachines

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Master mold fabricated using micro milling is an easy way to develop the polydimethylsiloxane (PDMS) based microfluidic device. Achieving high-quality micro-milled surface is important for excellent bonding strength between PDMS and glass slide. The aim of our experiment is to study the optimal cutting parameters for micro milling an aluminum mold insert for the production of a fine resolution microstructure with the minimum surface roughness using conventional computer numerical control (CNC) machine systems; we also aim to measure the bonding strength of PDMS with different surface roughnesses. Response surface methodology was employed to optimize the cutting parameters in order to obtain high surface smoothness. The cutting parameters were demonstrated with the following combinations: 20,000 rpm spindle speed, 50 mm/min feed rate, depth of cut 5 µm with tool size 200 µm or less; this gives a fine resolution microstructure with the minimum surface roughness and strong bonding strength between PDMS–PDMS and PDMS–glass.

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“…Optimization of these cutting parameters can greatly help in choosing the optimum cutting parameter for getting the required objective, i.e., minimum surface roughness and high material removal rate. Response surface method (RSM) is widely used for developing empirical relations between single and multiple responses [22][23][24]. The most critical factor that affects the output responses can also be determined with this method.…”

Section: Workpiece and Cutting Tool Materialsmentioning

confidence: 99%

“…Response surface method (RSM) is widely used for developing empirical relations between single and multiple responses [22][23][24]. The most critical factor that affects the output responses can also be determined with this method.…”

Section: Introductionmentioning

confidence: 99%

Investigations on Surface Roughness and Tool Wear Characteristics in Micro-Turning of Ti-6Al-4V Alloy

et al. 2020

Self Cite

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Micro-turning is a micro-mechanical cutting method used to produce small diameter cylindrical parts. Since the diameter of the part is usually small, it may be a little difficult to improve the surface quality by a second operation, such as grinding. Therefore, it is important to obtain the good surface finish in micro turning process using the ideal cutting parameters. Here, the multi-objective optimization of micro-turning process parameters such as cutting speed, feed rate and depth of cut were performed by response surface method (RSM). Two important machining indices, such as surface roughness and material removal rate, were simultaneously optimized in the micro-turning of a Ti6Al4V alloy. Further, the scanning electron microscope (SEM) analysis was done on the cutting tools. The overall results depict that the feed rate is the prominent factor that significantly affects the responses in micro-turning operation. Moreover, the SEM results confirmed that abrasion and crater wear mechanism were observed during the micro-turning of a Ti6Al4V alloy.

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Thermal analysis during turning of AZ31 magnesium alloy under dry and cryogenic conditions

Cited by 136 publications

References 38 publications

Development of a simulation model to study tool loads in pcBN when machining AISI 316L

Development of a simulation model to study tool loads in pcBN when machining AISI 316L

Study on the Optimum Cutting Parameters of an Aluminum Mold for Effective Bonding Strength of a PDMS Microfluidic Device

Investigations on Surface Roughness and Tool Wear Characteristics in Micro-Turning of Ti-6Al-4V Alloy

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