Turning modeling and simulation of an aerospace grade aluminum alloy using two-dimensional and three-dimensional finite element method

Abstract

This article presents the development of two-dimensional and three-dimensional finite element-based turning models, for better prediction of chip morphology and machined surface topology. Capabilities of a commercial finite element code Abaqus Ò /Explicit have been exploited to perform coupled temperature-displacement simulations of an aerospace grade aluminum alloy A2024-T351 machining. The findings show that two-dimensional cutting models predict chip morphologies and machined surface textures on a plane section (with unit thickness) passing through the center of workpiece width, and not at the edges. The contribution highlights the importance of three-dimensional machining models for a close corroboration of experimental and numerical results. Three-dimensional cutting simulations show that a small percentage of material volume flows toward workpiece edges (out of plane deformation), augmenting the contact pressures at the edges of tool rake face-workpiece interface. This enhances the burr formation process. Computational results concerning chip morphologies and cutting forces were found in good correlation with experimental ones. In the final part of the article, numerical simulation results with a modified version of a particular turning tool have been discussed. It has been found that the proposed geometry of the tool is helpful in reducing burr formation as well as cutting force amplitude during initial contact of cutting tool with the workpiece material.

Ultrasonic vibration-assisted micro-hole forming on skull

“…Many finite element models have been developed to study the material removal processes such as turning or drilling. 38,39 But, few studies were available on ultrasonic vibration-assisted hole penetration in bone. In this study, finite element analysis of tool–bone interaction was carried out with Abaqus/Explicit.…”

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

“…To model the material's behavior, Johnson-cook thermo-elasto-visco-plastic model, Equation (1), is used [26]. Promising results [7,12] show the effectiveness of the chosen stress model.…”

“…Provided material fracture toughness (K C ), Equation (6) is used to calculate the fracture energy (G f ). Equations (7) and (8) represent linear and exponential evolution of scalar damage evolution parameter (D) used in chip separation and chip regions, respectively.…”

“…As tool advances in the cutting direction (along x-axis) material deforms and flows in the similar direction (along x & y axes). However, some material also flows towards the workpiece edges along the z-axis (out of plane deformation) leading to side burr or poisson burr formation [7,8]. Therefore, around the central section of the workpiece (at Z = 0) purely end burr is formed, while near the edges (at Z = ±2), some material flows out of the plane along the z-axis, thus, a combination of end and poisson burr is formed.…”

“…Deburring processes increase the product cost and overall production time. Invaluable experimental and numerical efforts have been made in this context to comprehend burr formation mechanisms [2,3], model and predict burr sizes [4][5][6], control burr formation by tool geometry selection and tool path planning [7][8][9][10], and workpiece geometry design [11], etc. Researchers have also used heuristic optimization techniques to optimize various machining parameters like cutting speed, feed rate, depth of cut, tool angles, tool nose radius, etc., to minimize burr formation.…”