Two-Dimensional Finite Element Analysis of Turning Processes

Borsos, Benjámin; Csörgő, András; Hidas, Anna; Kotnyek, Bálint; Szabó, Attila; Kossa, Attila; Stépàn, Gábor

doi:10.3311/ppme.9283

Cited by 25 publications

(11 citation statements)

References 26 publications

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“…Researchers have used finite element method to predict the effect of machining parameters (cutting speed, depth of cut, tool geometry and feed rate) on the cutting forces, chip formation, temperature, stress and pressure distributions [41,42]. The results obtained from FEA have shown to be comparable with experimental results [43,44]. In this study, DEFORM 3D ® v11.0 software has been used to study orthogonal turning of Ti-6Al-4V alloy shown in Figure 1a.…”

Section: Finite Element Simulation On Deform 3dmentioning

confidence: 99%

Validation and optimization of cutting parameters for Ti-6Al-4V turning operation using DEFORM 3D simulations and Taguchi method

2021

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In this study, we show that optimising cutting forces as a machining response gave the most favourable conditions for turning of Ti-6Al-4V alloy. Using a combination of computational methods involving DEFORM simulations, Taguchi Design of Experiment (DOE) and analysis of variance (ANOVA), it was possible to minimise typical machining response such as the cutting force, cutting power and chip-tool interface temperature. The turning parameters that were varied in this study include cutting speed, depth of cut and feed rate. The optimum turning parameter combinations that would minimise the machining responses were established by using the “smaller the better” criterion and selecting the highest value of Signal to Noise Ratio. Confirmatory simulation revealed that using cutting speed of 120 m/min, 0.25 mm depth of cut and 0.1 mm/rev feed rate, the lowest cutting force of 88.21 N and chip-tool interface temperature of 387.24 °C can be obtained. Regression analysis indicated that the highest correlation coefficient of 0.97 was obtained between cutting forces and the turning parameters. The relationship between cutting forces and the turning parameters was linear since first-order regression model was sufficient.

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Section: Finite Element Simulation On Deform 3dmentioning

confidence: 99%

Validation and optimization of cutting parameters for Ti-6Al-4V turning operation using DEFORM 3D simulations and Taguchi method

2021

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“…The FE model consists of a 1000 × 300 µm 2D workpiece [21][22][23]. The tool is considered perfectly rigid and presents a rounded tip fillet whose radius is 0.75 µm.…”

Section: Abaqus Fe Modelmentioning

confidence: 99%

FEM and Analytical Modeling of the Incipient Chip Formation for the Generation of Micro-Features

et al. 2021

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This paper explores the modeling of incipient cutting by Abaqus, LS-Dyna, and Ansys Finite Element Methods (FEMs), by comparing also experimentally the results on different material classes, including common aluminum and steel alloys and an acetal polymer. The target application is the sustainable manufacturing of gecko adhesives by micromachining a durable mold for injection molding. The challenges posed by the mold shape include undercuts and sharp tips, which can be machined by a special diamond blade, which enters the material, forms a chip, and exits. An analytical model to predict the shape of the incipient chip and of the formed grove as a function of the material properties and of the cutting parameters is provided. The main scientific merit of the current work is to approach theoretically, numerically, and experimentally the very early phase of the cutting tool penetration for new sustainable machining and micro-machining processes.

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“…2 (e.g., grooved shaft). Cutting processing simulations are based on the energy generated in contact tool -metal chips, etc., cutting forces and cutting temperatures (contact tool -metal chips and on the very tool) [10,13]. For the purpose of a more complete analysis of numerical studies for simulations in the Third Wave AdvantEdge program, two mathematical models related to thermo-mechanical characteristics of the workpiece were used [14,15].…”

Section: Simulation Of Continuous and Discontinuous Turning Processmentioning

confidence: 99%

Numerical Analysis of the Temperature Field in the Cutting Zone in Continuous and Discontinuous Metal Cutting by Turning

et al. 2020

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Temperature of cutting is a very important indicator of the cutting process. High specific pressures and high temperatures in the narrow cutting zone result in a drop of hardness of the tool material, the intensification of the abrasion and deformation of the cutting elements, losing the cutting abilities, and finally the failure of the cutting tool. The aim of this paper is to calculate the temperature fields using the existing numerical models for the simulation of thermodynamic processes on the wedge of the cutting tool (based on the finite element method). A special accent is given to the numerical calculation of temperatures in the conditions of continuous and discontinuous turning for specific cutting conditions (processing regime, tool geometry and thermo-mechanical characteristics of the tool materials and workpiece materials) using different simulation models. The Third Wave AdvantEdge software package was used for the simulation of orthogonal turning, and some of the results of the calculations of the temperature fields were compared with the results of experimental measurements.

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Two-Dimensional Finite Element Analysis of Turning Processes

Abstract: Abstract

Cited by 25 publications

References 26 publications

Validation and optimization of cutting parameters for Ti-6Al-4V turning operation using DEFORM 3D simulations and Taguchi method

Validation and optimization of cutting parameters for Ti-6Al-4V turning operation using DEFORM 3D simulations and Taguchi method

FEM and Analytical Modeling of the Incipient Chip Formation for the Generation of Micro-Features

Numerical Analysis of the Temperature Field in the Cutting Zone in Continuous and Discontinuous Metal Cutting by Turning

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