3D stationary simulation of a turning operation with an Eulerian approach

Girinon, Mathieu; Valiorgue, Frédéric; Robin, Vincent; Feulvarch, Éric

doi:10.1016/j.applthermaleng.2014.11.006

Cited by 10 publications

(5 citation statements)

References 36 publications

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“…The Eulerian method takes a smaller amount of computation time, however, chip separation conditions and angle due to shearing action need to be defined earlier before simulation. 37 Form and dimensional features of chip are tough to predict while micromachining of titanium alloy. To overcome these issues, in this work, finite-element simulation is performed through implicit Lagrangian formulation.…”

Section: Fem Modelling and Methodologymentioning

confidence: 99%

Numerical simulation of the influence of tool geometry on energy consumption during micro turning of titanium alloy

Nijin

Jagadesh

2021

Proceedings of the Institution of Mechanical Engineers, Part E:

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Fabrication of an axisymmetric biomedical implant with good dimensions, form and surface integrity features are a challenging task in the micro-manufacturing industry. This is due to workpiece deflection, vibrations, tool wear and adhesion of the chip on the cutting inset during the micromachining process. So experimental evaluation on the variation of tool geometry is expensive and difficult as stated in prior literature. So, in this work, a finite-element method simulation is developed to comprehend the physics of the process and predict the energy consumption by incorporating the effect of material strengthening caused by shearing of material across the grain, shear band pattern upon strain rate and tool geometry such as edge radius, nose radius and rake angle. The modified Johnson-Cook material model is used to state the flow stress and an adaptive remeshing technique is utilized to model the plastic deformation at a higher strain rate during the simulation process. Initially, the model is developed in a transient state and then modified to a steady-state to obtain the output process parameters. The proposed model is calibrated and validated with experimental results reported in the literature. It is inferred that the cutting force, thrust force and feed force acquired from finite-element method simulation have been confirmed experimentally with prediction accuracy of 94%, 82.66% and 87.02%, respectively. It is also inferred that energy consumption during machining reduces with an increase in rake angle because of the sharpness of the cutting edge and less friction between tool and chip. An increase of nose radius and edge radius produces high thrust force and energy consumption and impedes high radial depth of cut. For the same machining parameters with the increase of edge radius and decrease of rake angle the mechanism of material removal changes from shearing to ploughing.

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Section: Fem Modelling and Methodologymentioning

confidence: 99%

Numerical simulation of the influence of tool geometry on energy consumption during micro turning of titanium alloy

Nijin

Jagadesh

2021

Proceedings of the Institution of Mechanical Engineers, Part E:

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“…The Eulerian method can perfectly solve the element deformation problems but it also has disadvantages. The chip shape needs to be known ahead of time, and the elastic behavior of the material is not considered, making the simulation of machining-induced residual stress not possible [5]. Therefore, Eulerian method is gradually replaced by other methods in cutting simulation.…”

Section: Introductionmentioning

confidence: 99%

“…Liu et al [14] and Tzotzis et al [15] simulated the cutting force of multiple sequential cuts in turning process, which is achieved by introducing the surface state after the previous cutting into the next cutting model as initial cutting condition [16]. Girinon et al [5] applied 3D Eulerian model to obtain the temperature distribution during cutting process of H13A material. Arrazola et al [17] simulated hard turning process through the 3D ALE model, and predicted the residual stress state of AISI 52100 steel on machined surface.…”

Section: Introductionmentioning

confidence: 99%

Numerical and experimental investigations on residual stress evolution of multiple sequential cuts in turning

Weng,

Zhou,

Zhang

et al. 2023

Int J Adv Manuf Technol

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Residual stress is of great importance on the fatigue life of components, nevertheless, most of the simulations of turning operation focus on the rst cut and ignore the evolution of residual stress in sequential cutting. The present study aims to explore the surface residual stress pro le along the feed direction during longitudinal turning, to understand the impact of sequential cuts on turning-induced residual stress. A Coupled Eulerian-Lagrangian (CEL)-based three-dimensional (3D) numerical model is employed to stably predict the evolution of residual stress of multiple sequential cuts in turning integrated with complete material removal process of each cut. The effectiveness and accuracy of the proposed model are veri ed though the good agreement between simulated and measured results. The results show that the surface residual stress gradually decreases with increasing cutting sequence under the condition of different tool nose radius and feed rates. It is also found that the main reason of this phenomenon is the initial stress state generated by the former tool path. For a single case, the drop of tensile residual stress from the rst cut to the third cut can be more signi cant when a larger feed rate is employed.

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“…[8] 1-50 β 1 0.9-0.98 [34] (or even 1) for many commercially available FEM software such as Deform, AdvantEdge or Forge NXT [8,[22][23][24] . For instance, Mathieu et al [25] and Cuesta et al [26] included this coefficient in their thermal analysis of different manufacturing processes. In contrast, other researchers defined the adiabatic self-heating as the ratio between the heat experimentally observed via thermal variations to the total plastic work done [27][28][29] , called as β 2 in this research.…”

Section: Introductionmentioning

confidence: 99%