Process simulations for 3D turning using uniform and variable microgeometry PCBN tools

Özel, Tuğrul

doi:10.1504/ijmmm.2008.020908

Cited by 11 publications

(11 citation statements)

References 10 publications

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“…Figure 2 depicts a standardized 80 • rhombic insert with its micro-geometry which comprises the cutting edge type, the chamfer angle and the chamfer width. In addition to the corner radius, the aforementioned parameters are crucial because they greatly affect the cutting forces during machining [20][21][22][23]. Moreover, according to Denkena et al [24] the cutting edge micro-geometry affects the tool life significantly due to changes in the characteristic tool wear behavior.…”

Section: Description Of Turning Insertsmentioning

confidence: 99%

CAD-Based Automated Design of FEA-Ready Cutting Tools

Tzotzis

García-Hernández

Talón

et al. 2020

JMMP

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The resources of modern Finite Element Analysis (FEA) software provide engineers with powerful mechanisms that can be used to investigate numerous machining processes with satisfying results. Nevertheless, the success of a simulation, especially in three dimensions, relies heavily on the accuracy of the cutting tool models that are implemented in the analyses. With this in mind, the present paper presents an application developed via Computer-Aided Design (CAD) programming that enables the automated design of accurate cutting tool models that can be used in 3D turning simulations. The presented application was developed with the aid of the programming resources of a commercially available CAD system. Moreover, the parametric design methodology was employed in order to design the tools according to the appropriate standards. Concluding, a sample tool model was tested by performing a number of machining simulations based on typical cutting parameters. The yielded results were then compared to experimental values of the generated machining force components for validation. The findings of the study prove the functionality of the tool models since a high level of agreement occurred between the acquired numerical results and the experimental ones.

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Section: Description Of Turning Insertsmentioning

confidence: 99%

CAD-Based Automated Design of FEA-Ready Cutting Tools

Tzotzis

García-Hernández

Talón

et al. 2020

JMMP

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“…An early example is the work of Guo and Liu [ 18 ], who developed a general practical explicit 3D finite element analysis (FEA) model for the analytical purposes of AISI-52100 hard turning with the use of polycrystalline cubic boron nitride (PCBN) inserts. Later, Karpat and Ozel [ 19 ] developed a 3D FEM-based model to predict forces and temperatures on various uniform and variable edge micro-geometry PCBN turning inserts. Malakizadi et al [ 20 ] presented a FEM-based approach to predict the flank wear for uncoated cemented carbide tools during conventional turning.…”

Section: Introductionmentioning

confidence: 99%

Influence of the Nose Radius on the Machining Forces Induced during AISI-4140 Hard Turning: A CAD-Based and 3D FEM Approach

et al. 2020

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The present study investigated the performance of three ceramic inserts in terms of the micro-geometry (nose radius and cutting edge type) with the aid of a 3D finite element (FE) model. A set of nine simulation runs was performed according to three levels of cutting speed and feed rate with respect to a predefined depth of cut and tool nose radius. The yielded results were compared to the experimental values that were acquired at identical cutting conditions as the simulated ones for verification purposes. Consequently, two more sets of nine simulations each were carried out so that a total of 27 turning simulation runs would adduce. The two extra sets corresponded to the same cutting conditions, but to different cutting tools (with varied nose radius). Moreover, a prediction model was established based on statistical methodologies such as the response surface methodology (RSM) and the analysis of variance (ANOVA), further investigating the relationship between the critical parameters (cutting speed, feed rate, and nose radius) and their influence on the generated turning force components. The comparison between the experimental values of the cutting force components and the simulated ones demonstrated an increased correlation that exceeded 89%. Similarly, the values derived from the statistical model were in compliance with the equivalent FE model values due to the verified adequacy.

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“…This study is concerned with finite element analysis of turning operation with PCBN Tool. AISI 1045 grade steel is machined with PCBN Cutting Tool.3D [7] turning operation is simulated and analyzed using FEM code DEFORM 3D.the distribution of effective stress, effective strain and strain rate in the work piece is studied. Finite element simulations were carried out for different cutting speeds and constant depth of cut feed rates with DEFORM-3D and Theoretical calculations separately.…”

Section: Resultsmentioning

confidence: 99%

Modeling and Simulation of Turning Operation

Swamy¹

2012

IOSRJMCE

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Turning is one of the metal cutting operation, is most widely used manufacturing technique in the industry and there are lots of studies to investigate this complex process in both academic and industrial world. Metal cutting operations still represent the largest class of manufacturing operations where turning is the most commonly employed material removal process. Advances in CNC/NC machining and high speed machining technologies have boosted the productivity of machining process. One of the state of the art efforts in manufacturing engineering is to use the FEM for simulation of the metal cutting process. Simulation can increase the understanding of the cutting process and reduce the number of experiments. Researchers find these variables by using experimental techniques which makes the investigation very time consuming and expensive. At this point, finite element modeling and simulation becomes main tool. These important cutting variables can be predicted without doing any experiment with finite element method. In this study the metal cutting process is analyzed with FEM model for 3D simulation of turning process with solid single point cutting tool. This tool is modeled with CATIAV5, and exported STL files and imported in DEFORM 3D. [1]

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Process simulations for 3D turning using uniform and variable microgeometry PCBN tools

Cited by 11 publications

References 10 publications

CAD-Based Automated Design of FEA-Ready Cutting Tools

CAD-Based Automated Design of FEA-Ready Cutting Tools

Influence of the Nose Radius on the Machining Forces Induced during AISI-4140 Hard Turning: A CAD-Based and 3D FEM Approach

Modeling and Simulation of Turning Operation

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