Finite element method study on the influence of initial stress on machining process

Ma, Yuan; Yu, Dingwen; Feng, Pingfa; Wu, Zhijun; Zhang, Chenglong

doi:10.1177/1687814015572457

Cited by 12 publications

(4 citation statements)

References 25 publications

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“…The chip morphology, the cutting force, and heat are easily obtained in the simulation software, and the method for getting the circumferential residual stress is detailed in Ma et al [17].…”

Section: Methodsmentioning

confidence: 99%

Sensitivity Analysis of Johnson-Cook Material Constants and Friction Coefficient Influence on Finite Element Simulation of Turning Inconel 718

et al. 2019

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The Johnson-Cook (J-C) constitutive model, including five material constants (A, B, n, C, m), and the Coulomb friction coefficient (μ) are critical preprocessed data in machining simulations. Before they become reliable preprocessed data, investigating these parameters’ effect on simulation results benefits parameter-selecting. This paper aims to investigate the different influence of five settings of the J-C constitutive equation and Coulomb friction coefficient on the turning simulation results of Inconel 718 under low-high cutting conditions, including residual stress, chip morphology, cutting force and temperature. A three-dimensional (3-D) finite element model was built, meanwhile, the reliability of the model was verified by comparing the experiment with the simulation. Sensitivity analysis of J-C parameters and friction coefficient on simulation results at low-high cutting conditions was carried out by the hybrid orthogonal test. The results demonstrate that the simulation accuracy of Inconel 718 is more susceptible to strain hardening and thermal softening in the J-C constitutive model. The friction coefficient only has significant effects on axial and radial forces in the high cutting condition. The influences of the coefficient A, n, and m on the residual stress, chip thickness, cutting force and temperature are especially significant. As the cutting parameters increase, the effect of the three coefficients will change visibly. This paper provides direction for controlling simulation results through the adjustment of the J-C constitutive model of Inconel 718 and the friction coefficient.

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Section: Methodsmentioning

confidence: 99%

Sensitivity Analysis of Johnson-Cook Material Constants and Friction Coefficient Influence on Finite Element Simulation of Turning Inconel 718

et al. 2019

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“…[16] have used a simplified analytical model of the cutting loads and stress-strain zone during cutting process based on research conducted by Ma, Feng, Zhang, Wu, & Yu (2016) [17]. Ma, Yu, Feng, Wu, & Zhang, (2015) [18] used a Finite Element Method (FEM) model and showed that initial tensile stress makes the cutting stress distribution within the workpiece become more tensile. This condition is caused by thermal effect from the cutting temperature.…”

Section: Introductionmentioning

confidence: 99%

Development of a cutting edge temperature measurement of end mill tool by using infrared radiation technique

Kiprawi

Yassin

Kamaruddin

et al. 2019

JMES

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This paper describes the development of cutting temperature measurement of end mill tool by using infrared radiation technique approach. Compared to conventional thermocouple technique, infrared radiation technique is an advance method of measuring temperature which featured high accuracy, high response rate, wide range of temperature scale detection and almost compatible with all materials used in the manufacturing industry. We measures the emission of infrared radiation from the source, which is cutting edge of tool by using photocells that contains InAs and InSb photovoltaic detectors. Photocells converts the infrared radiation to a voltage signal and then recorded by oscilloscope followed with a calibration with its corresponding temperature. This paper discussed about the calibration method, cutting experiment setup, the limit of infrared radiation level detected by photocells, signal correction of output signal, and relations of peak signal formation with rotation of end mill tool. The developed pyrometer is also capable to profile the cutting tool’s rotation based on the movements of infrared radiation’s emission at cutting tool’s edge. The conclusion was that the measurement of cutting temperature of high speed machining by using infrared radiation technique is possible. The developed pyrometer are capable to detect temperature changes at a span of 0.01 ms.

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“…This study is further studied by Ma et al [8] as they have simplified analytical model of the cutting loads and stress zone during cutting process. Ma et al [9] used a Finite Element Method (FEM) model and showed that initial tensile stress makes the cutting stress distribution within the workpiece become more tensile and diminishes the cutting forces and tool tip temperature.…”

Section: Introductionmentioning

confidence: 99%

Study of Cutting Edge Temperature and Cutting Force of End Mill Tool in High Speed Machining

et al. 2017

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Abstract.A wear of cutting tools during machining process is unavoidable due to the presence of frictional forces during removing process of unwanted material of workpiece. It is unavoidable but can be controlled at slower rate if the cutting speed is fixed at certain point in order to achieve optimum cutting conditions. The wear of cutting tools is closely related with the thermal deformations that occurred between the frictional contact point of cutting edge of cutting tool and workpiece. This research paper is focused on determinations of relationship among cutting temperature, cutting speed, cutting forces and radial depth of cutting parameters. The cutting temperature is determined by using the Indium Arsenide (InAs) and Indium Antimonide (InSb) photocells to measure infrared radiation that are emitted from cutting tools and cutting forces is determined by using dynamometer. The high speed machining process is done by end milling the outer surface of carbon steel. The signal from the photocell is digitally visualized in the digital oscilloscope. Based on the results, the cutting temperature increased as the radial depth and cutting speed increased. The cutting forces increased when radial depth increased but decreased when cutting speed is increased. The setup for calibration and discussion of the experiment will be explained in this paper.

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Finite element method study on the influence of initial stress on machining process

Cited by 12 publications

References 25 publications

Sensitivity Analysis of Johnson-Cook Material Constants and Friction Coefficient Influence on Finite Element Simulation of Turning Inconel 718

Sensitivity Analysis of Johnson-Cook Material Constants and Friction Coefficient Influence on Finite Element Simulation of Turning Inconel 718

Development of a cutting edge temperature measurement of end mill tool by using infrared radiation technique

Study of Cutting Edge Temperature and Cutting Force of End Mill Tool in High Speed Machining

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