Studying the Implementation of Finite Element Models in the Orthogonal Cutting Processes with Uncoated Tool and TiN, TiCN and Al2O3 Coated Tool
Main Article Content
Abstract
The metal machining is the most popular process used in the machinery part manufacturing. Therefore, machining process needs to be controlled by properly selecting of cutting condition, tool materials and coating to obtain the best machining time, good surface finish and low machining cost at the same time. To understand the effects of various cutting condition, tool and coating materials, it is useful to simulate the machining process using finite element techniques. This paper presents the preliminary investigation on the implementation of two dimensional finite element modeling (FEM) with two approaches, Lagrangian mesh description and Arbitrary Eulerian-Lagrangian (ALE) mesh description, to simulate the stress and cutting temperature in the orthogonal cutting processes. The influence of various tool and coating materials (TiN, TiCN and Al2O3 carbide coated tool, Polycrystalline Diamond - PCD) is also studied in comparison with uncoated tool. Titanium alloy Ti-6Al-4V and AISI 1045 steel is selected as work materials in these FEM models. The results show that the FEM model with ALE approach are adequate to simulate the stress and temperature distribution with a high accuracy while the FEM model with Lagrangian approach is capable in simulate chip formation.
Keywords
Finite element modeling, Machining simulation, AISI 1045 steel, Ti-6Al-4V, Coating
Article Details
References
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[11] Fahad, Muhammad, Paul T. Mativenga, and Mohammad A. Sheikh. "A comparative study of multilayer and functionally graded coated tools in high-speed machining." The International Journal of Advanced Manufacturing Technology 62, no. 1 (2012): 43-57.
[12] Schindler, S., M. Zimmermann, J. C. Aurich, and P. Steinmann. "Finite element model to calculate the thermal expansions of the tool and the workpiece in dry turning." Procedia CIRP 14 (2014): 535-540.
[13] Khanna, N., and Sangwan, K. S. “Machinability analysis of heat treated Ti64, Ti54M and Ti10. 2.3 titanium alloys.” International Journal of Precision Engineering and Manufacturing, 14(5), (2013): 719-724.
[2] Arrazola, P. J., I. Arriola, and M. A. Davies. "Analysis of the influence of tool type, coatings, and machinability on the thermal fields in orthogonal machining of AISI 4140 steels." CIRP Annals-Manufacturing Technology 58, no. 1 (2009): 85-88.
[3] Wu, Hong-bing, Chengguang Xu, Zhi-xin Jia, Xue-chang Zhang, and Gang Liu. "Establishment of constitutive model of titanium alloy Ti6Al4V and validation of finite element." In Measuring Technology and Mechatronics Automation (ICMTMA), 2010 International Conference on, vol. 2, pp. 141-144. IEEE, 2010.
[4] Klocke, Fritz, Dieter Lung, and Christoph Essig. "3D FEM model for the prediction of chip breakage." In Advanced Materials Research, vol. 223, pp. 142-151. Trans Tech Publications, 2011.
[5] Knight, Winston A., and Geoffrey Boothroyd. Fundamentals of metal machining and machine tools. Vol. 198. CRC Press, 2005.
[6] Johnson, Gordon R., and William H. Cook. "A constitutive model and data for metals subjected to large strains, high strain rates and high temperatures." In Proceedings of the 7th International Symposium on Ballistics, vol. 21, no. 1, pp. 541-547. 1983.
[7] Nasr, Mohamed NA. "Effects of sequential cuts on residual stresses when orthogonal cutting steel AISI 1045." Procedia CIRP 31 (2015): 118-123.
[8] Meyer, Hubert W., and David S. Kleponis. "Modeling the high strain rate behavior of titanium undergoing ballistic impact and penetration." International Journal of Impact Engineering 26, no. 1 (2001): 509-521.
[9] Duan, C. Z., T. Dou, Y. J. Cai, and Y. Y. Li. "Finite element simulation and experiment of chip formation process during high speed machining of AISI 1045 hardened steel." International Journal of Recent Trends in Engineering 1, no. 5 (2009): 46-50.
[10] Calamaz, Madalina, Dominique Coupard, and Franck Girot. "A new material model for 2D numerical simulation of serrated chip formation when machining titanium alloy Ti–6Al–4V." International Journal of Machine Tools and Manufacture 48, no. 3-4 (2008): 275-288.
[11] Fahad, Muhammad, Paul T. Mativenga, and Mohammad A. Sheikh. "A comparative study of multilayer and functionally graded coated tools in high-speed machining." The International Journal of Advanced Manufacturing Technology 62, no. 1 (2012): 43-57.
[12] Schindler, S., M. Zimmermann, J. C. Aurich, and P. Steinmann. "Finite element model to calculate the thermal expansions of the tool and the workpiece in dry turning." Procedia CIRP 14 (2014): 535-540.
[13] Khanna, N., and Sangwan, K. S. “Machinability analysis of heat treated Ti64, Ti54M and Ti10. 2.3 titanium alloys.” International Journal of Precision Engineering and Manufacturing, 14(5), (2013): 719-724.