An experimental and coupled thermo-mechanical finite element study of heat partition effects in machining

Akbar, Faraz; Mativenga, Paul; Sheikh, Mohammad

doi:10.1007/s00170-009-2117-5

Cited by 64 publications

(35 citation statements)

References 53 publications

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“…One of the disadvantages of the Lagrangian formulation is that due to the large deformations occurring in a machining process it will inevitably lead to excessive element distortion in the mesh. Finite element models that use this type of formulation require a chip separation criterion to enable for the chip to come off the workpiece [6,16]. Remeshing can also be adopted to reduce the element distortion [9,30,37].…”

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

“…The finite element model results showed that the formation of the chip resulting from the intrinsic behavior of the material was realistic. The influence of temperature and heat partition at the tool rake face, on the tool wear mechanism was analyzed by F. Akbar et al [5] simulated orthogonal turning operation for AISI 4140 steel using tungsten based cemented carbide cutting tools and concluded that the prediction of machining process needs an accurate determination of heat partition between tool-chip interface. Large strain deformation response of Al 6061-T6 had been studied by D. R. Lesuer et al [6] over a range of strain-rates from 10 -4 s -1 to 10 4 s -1 to critically calculate the strength and damage components of Johnson Cook (JC) material model.…”

Section: Literature Reviewmentioning

confidence: 99%

“…Since, no change in material cross-section was assumed, the two dimensional model with plane strain formulation provides reliable results [3], [5], [10], [11]. The machining operation was also considered orthogonal, which represents the turning conditions adequately [3], [5], [10], [11].…”

Section: Finite Element Modellingmentioning

confidence: 99%

“…Johnson-Cook (JC) material model was used for the Al-6061 work piece material. This model is suitable for problems where strain-rates vary over a large range (10 2 -10 6 s -1 ) [3], [5]. The JC model is capable of predicting the plastic deformation as well as damage and failure.…”

Section: Finite Element Modellingmentioning

confidence: 99%

“…The JC model is capable of predicting the plastic deformation as well as damage and failure. The stress in plastic deformation regime is given by the following equation [3]- [5], [11], [13]- [15]:…”

Section: Finite Element Modellingmentioning

confidence: 99%

See 2 more Smart Citations

A Numerical Investigation of Effects of Cutting Velocity and Feed Rate on Residual Stresses in Aluminum Alloy Al-6061

Akram¹,

Jaffery²,

Khan³

et al. 2015

IJMMM

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Abstract-The aim of this research was to investigate the residual stresses in an aluminum alloy Al-6061 workpiece after machining. The sensitivity of residual stresses to cutting speed and feed rate was determined using finite element method. Tensile residual stresses at the surface of components are generally undesirable as they contribute to fatigue failure, quench cracking and stress-corrosion cracking. A two dimensional model of machining was developed using commercially available finite element software, Abaqus, to simulate orthogonal cutting of Al-6061 alloy. Numerical simulations of orthogonal cutting of the workpiece were carried out at various preselected combinations of feed rate and cutting speed. The simulation results showed that residual stresses were insensitive to changes in cutting speed, however, residual stresses were clearly affected by the change in feed rate.

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Studies on Machining of Hard Materials

Patel

Chate

Parappagoudar³

et al. 2020

SpringerBriefs in Applied Sciences and Technology

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An experimental and coupled thermo-mechanical finite element study of heat partition effects in machining

Cited by 64 publications

References 53 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

A Numerical Investigation of Effects of Cutting Velocity and Feed Rate on Residual Stresses in Aluminum Alloy Al-6061

Studies on Machining of Hard Materials

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