Thermo-elastic deformations of the workpiece when dry turning aluminum alloys - A finite element model to predict thermal effects in the workpiece

Schindler, Stefan; Zimmermann, Marco; Aurich, Jan C.; Steinmann, Paul

doi:10.1016/j.cirpj.2014.04.006

Cited by 25 publications

(8 citation statements)

References 32 publications

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“…The research of XXX also established a relationship between cutting time and tool wear and found it linear in the nominal wear stage 29 . A relationship between the actual and nominal depth of cut was also revealed 30 .…”

Section: With This Regard Efficient Methods To Model Practical Manufmentioning

confidence: 97%

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A novel representation method of non-ideal surface morphologies and its application in shaft-hole sealing simulation analysis

Qiao

Zhu³

et al. 2017

Proceedings of the Institution of Mechanical Engineers, Part B:

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Assembly process simulation has been recognized as an effective tool for design verification. The representation of actual part surfaces produced by manufacturing processes is an important issue for assembly simulation. Manufactured part surfaces can also be regarded as non-ideal surface morphologies caused by manufacturing errors. This paper presents a new approach to describe non-ideal cylindrical surface morphologies. A deviation coordinate system is developed by adding a new deviation dimension along the normal direction of the nominal surface modelled in the cylindrical surface curvilinear coordinate system. Considering characteristics of the cylindrical surface machining process, a unified expression of combined Hermite polynomials and Fourier series is used to demonstrate variations that commonly appear on manufactured non-ideal cylindrical surfaces. The Hermite-Fourier polynomials constitute multimorphologies resulting from different manufacturing errors. In the proposed method, a parametric matrix is created from the expansion of the Hermite-Fourier polynomials. Each morphology can be represented by a corresponding matrix. The total deviation of a non-ideal part surface is the sum of deviations caused by each manufacturing error source through a linear combination of various matrices. The effectiveness of the proposed method is verified by a simulation of the sealing function of shaft-hole assemblies.

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Section: With This Regard Efficient Methods To Model Practical Manufmentioning

confidence: 97%

“…26,27 Stavropoulos et al 28 established the relationship between cutting time and tool wear and found it is linear in the nominal wear stage. Schindler et al 29 proposed a finite element method to predict the deformations caused by thermal effects when dry turning aluminum alloys.…”

Section: Introductionmentioning

confidence: 99%

A novel representation method of non-ideal surface morphologies and its application in shaft-hole sealing simulation analysis

Qiao

Zhu³

et al. 2017

Proceedings of the Institution of Mechanical Engineers, Part B:

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“…For this purpose, additional experiments can be carried out, as described in detail in [18]. An alternative, effort-saving method is described in Sect.…”

Section: Experimental Designmentioning

confidence: 99%

Identification of thermal effects on the diameter deviation of inhomogeneous aluminum metal matrix composite workpieces when dry turning

Schindler

Zimmermann

Aurich

et al. 2015

Prod. Eng. Res. Devel.

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The use of dry cutting is associated with considerable thermal loads on the machine tool, the tool and the workpiece because of the missing heat convection through the cutting fluid. These thermal loads cause thermal expansions of the components. The accuracy of machining is thus decreased. In recent years, particularly the thermal expansions of the workpiece and the tool attained significance due to the increased demands on the machining accuracy. Aluminum metal matrix composites (Al-MMCs) show a poor machinability due to the reinforcement of light metal alloys via hard and abrasive materials. Dry turning of such composites is therefore accompanied with high thermal workpiece and tool loads. In this paper, finite element models of the workpiece and the tool are used in order to calculate the temperature distribution and thus the thermally induced expansion of the workpiece and the tool when turning AL-MMC regarding the cutting condition used. The removal of material and the heat flow to the environment are considered. The required boundary conditions (e.g. the heat flow into the workpiece) for the simulations were determined using experimental results. A new evaluation method of experimental diameter measurement validates the numerically calculated diameter deviations and reveals a considerable effect of the thermal expansions of the workpiece and the tool on the accuracy of machining.

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“…Results indicated that the feed has a major contribution in determining a better surface finish compared to coolant flow rate and cutting speed. Schindler et al (2014) investigated the thermo-elastic deformation of the aluminum alloy under dry machining conditions with help of a finite element model. The authors concluded that the workpiece temperature depended upon heat flux produced due to cutting forces and heat dissipation towards the surrounding.…”

Section: Introductionmentioning

confidence: 99%

Experimental Investigation and Optimization of Machining Parameters in Turning of Aluminum Alloy 075-T651

Srivastava

Verma

Niranjan

et al. 2021

Production Engineering Archives

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Aluminum alloy 7075-T651 is a widely used material in the aviation, marine, and automobile sectors. The wide application marks the importance of this material’s research in the manufacturing field. This research focuses on optimizing input process parameters of the turning process in the machining of Aluminum 7075-T651 with a tungsten carbide insert. The input machining parameters are cutting speed, feed, and depth of cut for the output response parameters cutting force, feed force, radial force, material removal, and surface roughness of the workpiece. For optimization of process parameters, the Taguchi method, with standard L9 orthogonal array, is used. ANOVA is applied to obtain signifi-cant factors and optimal combinations of process parameters.

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Thermo-elastic deformations of the workpiece when dry turning aluminum alloys - A finite element model to predict thermal effects in the workpiece

Cited by 25 publications

References 32 publications

A novel representation method of non-ideal surface morphologies and its application in shaft-hole sealing simulation analysis

A novel representation method of non-ideal surface morphologies and its application in shaft-hole sealing simulation analysis

Identification of thermal effects on the diameter deviation of inhomogeneous aluminum metal matrix composite workpieces when dry turning

Experimental Investigation and Optimization of Machining Parameters in Turning of Aluminum Alloy 075-T651

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