Segmented and mathematical model for 3D FEM tapping simulation to predict the relative torque before tool production

Oezkaya, Ekrem; Biermann, Dirk

doi:10.1016/j.ijmecsci.2017.04.011

Cited by 23 publications

(10 citation statements)

References 22 publications

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“…Accordingly, the dimensionless Young modulus of the equivalent virtual material * becomes bigger. Equation (6) shows that a bigger * gives rise to a larger ].…”

Section: Summary Of Resultsmentioning

confidence: 99%

“…On the other hand, studies belonging to the latter group often rely on simulations for the modeling of joint interfaces, especially those used for engineering applications. At this time, finite element analysis (FEA) technique including modeling and simulation is one of the most commonly used methods for studying the dynamic characteristics of mechanical structures [6]. Several common methods in FEA involve the use of beam element [7], Iwan's model [8,9], and spring-damper system [10,11].…”

Section: Introductionmentioning

confidence: 99%

See 1 more Smart Citation

Inverse Identification of Virtual Material Parameters Using Surface Response Methodology

Cui

Hua

et al. 2018

Mathematical Problems in Engineering

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The virtual material model is now widely applied for modeling the dynamical performance of assembled structures since it can effectively represent the complicated contact behavior of joint interfaces despite being relatively simple to create. In this study, a virtual material model is adopted for modeling the dominant physics of a bolted joint subject to a set of pretightening conditions. The unknown virtual material parameters are acquired by an inverse identification procedure that uses the surface response methodology. The greatest advantage of this approach is the ease with which it acquires the joint parameters without taking apart a built-up structure to do special measurements on each separated component. Intricate theoretical calculations can also be avoided when this method is used. This study addresses the responses of virtual material parameters under different pretightening considerations. Predictions based on the identified virtual material parameters are compared with the corresponding results obtained using the analytical method. The correlation between the two sets of results at all preload levels is promising, which indicates the successful identification of the virtual material parameters.

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“…Accordingly, the dimensionless Young modulus of the equivalent virtual material * becomes bigger. Equation (6) shows that a bigger * gives rise to a larger ].…”

Section: Summary Of Resultsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Inverse Identification of Virtual Material Parameters Using Surface Response Methodology

Cui

Hua

et al. 2018

Mathematical Problems in Engineering

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show abstract

“…A numerical approach for torque and force prediction in tapping processes, that has made huge progress over the last years, is the finite element method (FEM). However, since cutting simulation using FE-modelling is a challenging task and requires plenty of computing time, Oezkaya and Biermann use a segmented workpiece model to significantly reduce the simulation time for a single thread to 170 h [17]. To further reduce the high computing time the authors develop a geometrical torque prediction method based on the simulated forces to determine the relative torque for different tapping tools and diameters [18].…”

Section: State Of the Artmentioning

confidence: 99%

Measuring and modelling of process forces during tapping using single tooth analogy process

Geßner¹,

Weigold²,

Abele³

2020

Prod. Eng. Res. Devel.

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For machining internal threads, tapping is a commonly used process. However, due to the complex geometry of the tapping tool, each tooth has a unique geometry resulting in individual forces. Since the forces act synchronously during the process, they partly compensate each other. However, since resulting forces in tapping can cause undesired deflection of the tool which can lead to threads that are not true to gauge or tool breakage, the knowledge of the forces is crucial. To predict the occurring forces on each tooth, different modelling approaches can be used. An approach based on the chip load-cutting force relationship is the mechanistic modelling. Therefore, a suitable force model is of central importance. An empirical force model can be established using an analogy process. Within this work a single tooth analogy process is presented to measure the forces of each tooth separately. By means of a geometrical analysis of the real tool, the chip sizes, such as the cross-section area of the undeformed chip are calculated. Merging the measured process forces from the analogy process and the actual chip sizes, an empirical force model is set up using multivariate regression. The model is validated by implementing it in an existing framework and comparing the results to experimental data.

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“…The micro-structure of the tapping surface reveals that the area affected by the ATVAT and the AVAT type of tapping method is less than that by the CT method. Aiming to the problem where the development of traditional tapping tool is usually composed by the expensive investigation and experiment, a method was proposed by Ekrem Oezkaya and Dirk Biermann [13] in 2017 upholding that such method can be used during the design stage to estimate the relative torque so as to save the resources, energy and cost. Based on the referential simulation model that accords with the experiment result, the lengthy calculation time issue can be solved through the appropriate segmentation method.…”

Section: Introductionmentioning

confidence: 99%

Analysis of the Micro-type Circular Rod Screw Thread Machining Process

Chen

Ting

Wang

2021

Preprint

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The main purpose of this research is to study the analysis of the screw thread machining process for micro-type circular rods. During the analysis, the SUS304 stainless steel micro-type circular rod is used to analyze the micro thread machining process for the circular rod that will be fabricated according to varied outer diameters (Ø1.9mm, Ø1.94mm and Ø2mm), varied pitches (0.25mm and 0.4mm), and specific friction factors (0.1, 0.2, 0.3, 0.5 and 0.7). Through the micro material parameters with scale factors being corrected, the finite element analysis is conducted in order to learn about the effect of pitches and friction factors on the screw threads of the micro-type circular rod during the machining process. During the research, the finite element analysis was also conducted through the use of full integration rule and by coupling the shape function, as being inferred from the 3D tetrahedral element with 4 corner nodes, in the stiffness matrix. This research focuses on the simulation of comprehensive forming resume data, stress/strain distribution and thread shape distribution relating to the thread machining process for the micro-type circular rod. In the meantime, the micro-type circular rod screw thread machining die is also designed for carrying out the micro-type thread machining experiment for the SUS304 micro-type circular rod. The outcome is also compared with the simulation result to verify the reliability of the aforesaid analysis method. During the research, the difference between traditional material parameters and that of the corrected micro dimensions is also analyzed with the result provided below: The simulation result of the corrected material parameters indicated that the maximum principal stress tends to grow along with the enlarging of the pitch, but there isn’t a visible difference between the maximum principal strain and the material parameters being used before and after the modification. When the friction factors are changing during the micro-type circular rod screw thread machining process, its torsional, stress, and strain force tends to grow along with the increase of friction factors.

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Segmented and mathematical model for 3D FEM tapping simulation to predict the relative torque before tool production

Cited by 23 publications

References 22 publications

Inverse Identification of Virtual Material Parameters Using Surface Response Methodology

Inverse Identification of Virtual Material Parameters Using Surface Response Methodology

Measuring and modelling of process forces during tapping using single tooth analogy process

Analysis of the Micro-type Circular Rod Screw Thread Machining Process

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