Establish Using FEM Method of Constitutive Model for Chip Formation in the Cutting Process of Gray Cast Iron

The application of finite element models is a promising method for ensuring part quality during machining to accurately predict induced residual stresses and cutting forces. The present study applied Analysis System software to formulate a 3D model to predict induced residual stress and forces for AISI 1020 alloy. Taguchi method was applied in the design of the experiment with three levels and three factors selected: Cutting speed, feed rate and depth of cut. For validation, stresses are measured using an x-ray diffractometer from the surface to a depth of 0.6 mm in steps of 0.2 mm. The cutting forces are determined using a force dynamometer. Simulation results showed that cutting speed, feed rate and depth of cut contributed 94.76 %, 0.048 %, and 0.11 % respectively. The predictive model equations were statistically significant with a p-value of < 0.005. The average induced residual stress on the superficial layer from the experiment and simulation were À 367.7 MPa and À 365.6 MPa respectively. The average residual stresses obtained at depths of 0.2 mm, 0.4 mm, and 0.6 mm were À 260 MPa, À 233 MPa, and À 211 MPa, respectively. The proposed model offers a potential solution to reducing the costs of experimental methods.

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“…Based on Equation 5, the total heat generated can be calculated, Equation 6 [22–26].

\vcenter{\openup.5em\halign{$\displaystyle{#}$\cr \dot{{Q}_{g}}={\eta }_{p}\dot{{W}_{p}+{\eta }_{F}\dot{{W}_{F}=}}{\eta }_{p}\left(\sigma \dot{{\varepsilon{} }_{p}}\right)+{\eta }_{F}\left(\tau {V}_{Ch}\right)\hfill\cr}}

…”

Section: Present Finite Element Modelling Using Ansys Softwarementioning

confidence: 99%

Finite element based model for predicting induced residual stresses and cutting forces in AISI 1020 steel alloy

Bosire

Muvengei

Mutua

et al. 2023

Materialwissenschaft Werkst

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“…In order to determine the chip morphologies of polymers from the real stress-strain curve, cutting force and chip formation are predicted from the true stress-strain relation [80].In order to illustrate the most current developments in the uses of FEM techniques in CNC machining processes, numerical approaches for the modelling of chip production are examined [81].To accelerate material removal rate during machining operations, a boundary condition for chip production in the cutting process of grey cast iron utilizing fem technique is created [82].As a consequence, chip morphologies, mechanisms of chip generation, prediction of chip shape and material removal rates during machining operations of different workpiece materials and machining strategies can be accurately precited and analyzed using FEM simulation.…”

Section: Chip Formation Processmentioning

confidence: 99%

Modification of CNC Machine Tool Operations and Structures Using Finite Element Methods: A Review

2023

jjmie

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To increase accuracy as well as productivity in CNC machine tools, Finite Element Methods (FEM) are applied to the machining operations and machine tool structures. As a result, the errors of machining operations can be analyzed and minimized in order to enhance accuracy of machined parts. Also, by analyzing the stress and deformations of the machine tool elements under actual loads, performances as well as working life of the machine tool structures can be enhanced. The study reviews the analysis and modification of CNC machine tool operations and structures using finite element methods from the recent published papers. Applications of the FEM methods in the simulation of cutting temperatures, cutting forces and energy consumption, chip formation, deflection and deformation errors of thin-walled components, and tool wear rate during machining processes are reviewed to demonstrate the capabilities of the FEM simulation in CNC machining modification. Furthermore, applications of theFEM tosimulate various machine tool components such as the bed, ball screw, spindle, and guideways are studied in order to enhance the performances of various machine tool elements such as mechanical properties in real-world working situations.In order to fill the gaps between the existing studies and published papers, innovative concepts and approaches of future research works are also suggested. Thus, the research field can be developed by reviewing and analyzing previous achievements in published research works in order to offer innovative concepts and approaches in applications of FEM techniques in modifying machining procedures and CNC machine tool structures.

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“…Some studies recommend using polycrystalline cubic boron nitride (pcBN) for highspeed processing of cast iron [13][14][15], but this cannot be applied in the case of the trimming dies used to clean anode supports. In addition, in addition to the possibility of conducting experimental research on cast iron cutting processes, cutting simulation methods can be applied, such as the finite element method (FEM), which allows us to obtain information on the process of splinter formation, distribution voltages, temperature distribution [16][17][18][19].…”

Section: Introductionmentioning

confidence: 99%

Increasing the Durability of Trimming Dies Used to Clean Anodes in the Aluminum Industry

Gârleanu

Borda

Gârleanu

et al. 2021

Metals

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Increasing the durability of trimming dies used to clean anodes is a very important goal in order to reduce the costs involved in obtaining aluminum. The research focused both on choosing an optimal material for the execution of trimming dies and on the application of technologies for plating active areas and, at the same time, on optimizing the geometric shape of the active area of the trimming die. In order to choose an optimal material from which to make the trimming dies, it was taken into account that they are usually made of X210Cr12 steel. In the stage of choosing an optimal material for the execution of the trimming dies, five steels were taken into account, namely: K105, K107, K110, K360, and K460. Analyses of the metallographic structure of the passage area were performed between the metal deposited by welding and the base material, demonstrating the fact that hot welding plating allows obtaining a more homogeneous metallographic structure compared to cold welding plating. The choice of new material was not a solution to increase the durability of the trimming die. Change in the trimming die geometry determined a reduction in deformations of about 13.8 times and of the equivalent stresses of about 7 times compared to those obtained in the case of the old trimming die. In addition, the durability of the trimming die with the new construction shape increases approximately three times compared to the trimming die with the old geometric shape. This demonstrates that the solution to increasing the durability of the trimming die is to adopt an optimal geometry of the active part at the expense of choosing an optimal material.

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Establish Using FEM Method of Constitutive Model for Chip Formation in the Cutting Process of Gray Cast Iron

Cited by 6 publications

References 37 publications

Finite element based model for predicting induced residual stresses and cutting forces in AISI 1020 steel alloy

Finite element based model for predicting induced residual stresses and cutting forces in AISI 1020 steel alloy

Modification of CNC Machine Tool Operations and Structures Using Finite Element Methods: A Review

Increasing the Durability of Trimming Dies Used to Clean Anodes in the Aluminum Industry

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