IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology.
Finite Element Modelling of Chip Formation in Orthogonal Machining for AISI 1050paperpublications3
Abstract: Finite element method has gained immense popularity in the area of metal cutting for providing detailed insight in to the chip formation process. This report presents an overview of the application of finite element method in the study of metal cutting process. The basics of both metal cutting and finite element methods, being the foremost in understanding the applicability of finite element method in metal cutting, have been discussed in brief. In this project, thermo mechanical simulation of turning process has been developed using commercially available finite element analysis software, ABAQUS 6.10. A 2-D orthogonal cutting has been modelled using an Arbitrary Lagrangian - Eulerian (ALE) formulation. The Johnson-Cook plasticity model has been assumed to describe the material behaviour during the process. Adaptive meshing dynamic explicit is also employed in this model to avoid the severe deformation. This study is aimed at temperature and stresses distributions during machining of AISI 1050 steel with three different speed 120m/min, feed 0.1 mm/rev. and depth of cut 1.5 mm. The results showed for speed 120 m/min, feed 0.1 and depth of cut 1.5 that the maximum stress for -7oC rake angle is 1.35 GPa while the maximum temperature results shown that 699°C.
Parametric analysis and multi objective optimization of cutting parameters in...eSAT Publishing House
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
Parametric analysis and multi objective optimization of cutting parameters in...eSAT Journals
Abstract Modern manufacturers, seeking to remain competitive in the market, rely on their Manufacturing engineers and production personnel to quickly and effectively set up manufacturing processes for new products. This paper presents the multi response optimization of turning parameters for Turning on AISI 4340 Alloy Steel. Experiments are designed and conducted based on Taguchi’s L27 Orthogonal array design. This paper discusses an investigation into the use of Taguchi parameter Design and Regression analysis to predict and optimize the Surface Roughness, Metal Removal Rate and Power Consumption in turning operations using CVD Cutting Tool. The Analysis of Variance (ANOVA) is employed to analyze the influence of Process Parameters during Turning. This paper also remarks the advantages of multi-objective optimization approach over the single-objective one. The useful results have been obtained by this research for other similar type of studies and can be helpful for further research works on the Tool life and Vibration of tools etc. Keywords: Turning, Ra, MRR, PC, Taguchi, Anova etc…
NUMERICAL AND EXPERIMENTAL VALIDATION OF CHIP MORPHOLOGYIAEME Publication
The extensive research studies are used to divination the behavior of complex
Metal cutting processes. The cutting parameters such as speed, feed and force play
important role on conform chip morphology. The experimental techniques for
investigation the chip morphology is expensive and time consuming. To overcome
these difficulties Finite element modeling and simulation process are used as effective
tool to divination the effect of cutting variables. In the present study FEA simulation
process model is developed to divination the chip morphology and cutting forces in
turning of Al-6061 with WC tool. Johnson cook material models are considered for
visco-elastic material behavior. The obtained simulation process results are compared
with experimental process results
International Journal of Engineering Research and Development (IJERD)IJERD Editor
International Journal of Engineering Research and Development is an international premier peer reviewed open access engineering and technology journal promoting the discovery, innovation, advancement and dissemination of basic and transitional knowledge in engineering, technology and related disciplines.
Finite Element Simulation of Serrated Chip Formation in High Speed CuttingIJRES Journal
The description of high speed cutting process with simulation based on finite element method provides huge superiorities compared to analytical and experimental models. This work focused on the study of high speed cutting process with finite element method, using commercial software ABAQUS/Explicit. The chip morphology is predicted, and the stress, strain and temperature in the chip are all simulated vividly when cutting stably. The serrated chip formation is explained by the adiabatic shear theory. The results showed that it is better to use the adiabatic shear theory to explain the formation of serrated chip.
Finite Element Modelling of Chip Formation in Orthogonal Machining for AISI 1050paperpublications3
Abstract: Finite element method has gained immense popularity in the area of metal cutting for providing detailed insight in to the chip formation process. This report presents an overview of the application of finite element method in the study of metal cutting process. The basics of both metal cutting and finite element methods, being the foremost in understanding the applicability of finite element method in metal cutting, have been discussed in brief. In this project, thermo mechanical simulation of turning process has been developed using commercially available finite element analysis software, ABAQUS 6.10. A 2-D orthogonal cutting has been modelled using an Arbitrary Lagrangian - Eulerian (ALE) formulation. The Johnson-Cook plasticity model has been assumed to describe the material behaviour during the process. Adaptive meshing dynamic explicit is also employed in this model to avoid the severe deformation. This study is aimed at temperature and stresses distributions during machining of AISI 1050 steel with three different speed 120m/min, feed 0.1 mm/rev. and depth of cut 1.5 mm. The results showed for speed 120 m/min, feed 0.1 and depth of cut 1.5 that the maximum stress for -7oC rake angle is 1.35 GPa while the maximum temperature results shown that 699°C.
Parametric analysis and multi objective optimization of cutting parameters in...eSAT Publishing House
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
Parametric analysis and multi objective optimization of cutting parameters in...eSAT Journals
Abstract Modern manufacturers, seeking to remain competitive in the market, rely on their Manufacturing engineers and production personnel to quickly and effectively set up manufacturing processes for new products. This paper presents the multi response optimization of turning parameters for Turning on AISI 4340 Alloy Steel. Experiments are designed and conducted based on Taguchi’s L27 Orthogonal array design. This paper discusses an investigation into the use of Taguchi parameter Design and Regression analysis to predict and optimize the Surface Roughness, Metal Removal Rate and Power Consumption in turning operations using CVD Cutting Tool. The Analysis of Variance (ANOVA) is employed to analyze the influence of Process Parameters during Turning. This paper also remarks the advantages of multi-objective optimization approach over the single-objective one. The useful results have been obtained by this research for other similar type of studies and can be helpful for further research works on the Tool life and Vibration of tools etc. Keywords: Turning, Ra, MRR, PC, Taguchi, Anova etc…
NUMERICAL AND EXPERIMENTAL VALIDATION OF CHIP MORPHOLOGYIAEME Publication
The extensive research studies are used to divination the behavior of complex
Metal cutting processes. The cutting parameters such as speed, feed and force play
important role on conform chip morphology. The experimental techniques for
investigation the chip morphology is expensive and time consuming. To overcome
these difficulties Finite element modeling and simulation process are used as effective
tool to divination the effect of cutting variables. In the present study FEA simulation
process model is developed to divination the chip morphology and cutting forces in
turning of Al-6061 with WC tool. Johnson cook material models are considered for
visco-elastic material behavior. The obtained simulation process results are compared
with experimental process results
International Journal of Engineering Research and Development (IJERD)IJERD Editor
International Journal of Engineering Research and Development is an international premier peer reviewed open access engineering and technology journal promoting the discovery, innovation, advancement and dissemination of basic and transitional knowledge in engineering, technology and related disciplines.
Finite Element Simulation of Serrated Chip Formation in High Speed CuttingIJRES Journal
The description of high speed cutting process with simulation based on finite element method provides huge superiorities compared to analytical and experimental models. This work focused on the study of high speed cutting process with finite element method, using commercial software ABAQUS/Explicit. The chip morphology is predicted, and the stress, strain and temperature in the chip are all simulated vividly when cutting stably. The serrated chip formation is explained by the adiabatic shear theory. The results showed that it is better to use the adiabatic shear theory to explain the formation of serrated chip.
Finite Element Simulation and Experiment of Chip Formation Process during Hig...IDES Editor
As an advanced manufacturing technology which
has been developed rapidly in recent years, high speed
machining is widely applied in many industries. The chip
formation during high speed machining is a complicated
material deformation and removing process. In research area
of high speed machining, the prediction of chip morphology is
a hot and difficult topic. A finite element method based on the
software ABAOUS which involves Johnson-Cook material
model and fracture criterion was used to simulate the serrated
chip morphology and cutting force during high speed
machining of AISI 1045 hardened steel. The serrated chip
morphology and cutting force were observed and measured by
high speed machining experiment of AISI 1045 hardened steel.
The effects of rake angle on cutting force, sawtooth degree
and space between sawteeth were discussed. The investigation
indicates that the simulation results are consistent with the
experiments and this finite element simulation method
presented can be used to predict the chip morphology and
cutting force accurately during high speed machining of
hardened steel.
The quality of the machined piece and tool life are greatly influenced by determination of
maximum temperature of the cutting tool. Numerous researchers have approached to solve this problem
with experimental, analytical and numerical analysis. There is hardly a consensus on the basics principles
of the thermal problem in metal cutting, even though considerable research effort has been made on it. It is
exceedingly difficult to predict in a precise manner the performance of tool for the machining process. This
paper reviews work on the requirements for optimization of Tool wear so that its life could easily be
predicted
A Review on Experimental Investigation of Machining Parameters during CNC Mac...IJERA Editor
This review paper aims towards the optimization of CNC turning operation when used over an OHNS material.
The lathe machine was chosen because of its widespread availability and its ability to perform various tasks
without much change in its structure. Also using lathe machines is very cheap and hence it is beneficial from
economic point of view as well. The turning operation was specifically chosen because of the various
advantages that it offers. It can be used for machining a large variety of materials and it is cheaper than milling.
OHNS (Oil Hardened Non Shrinking) tool was chosen due to its hardness. These materials are used only for
dies so it was chosen so that its industrial usage could be exploited. To comprehend the usage, all the input and
output parameters that could affect the machining process, namely input parameters like feed, cutting
conditions, speed, etc. and output parameters like surface roughness, surface finish, material removal rate were
analyzed using the researches that had already been done on CNC turning. After careful study of a variety of
research papers on this topic, it was decided that several input as well as the output parameters would be
considered which included feed, depth of cut and cutting speed were taken as the input parameters whereas
Material Removal Rate (MRR) and surface finish were taken as the output parameters. From the results of the
research papers, it was concluded that feed, depth of cut and cutting speed could be chosen as input parameters
whereas MRR and surface finish would be the output parameters
Optimization of machining parameters on tool tip temperature by using vegetab...eSAT Journals
Abstract
In this research the experiments were performed by using vegetable oil to know the effect of different machining parameters on
tool tip temperature. The quality of work piece material is main contributing factor in these days which may be influence by heat
generated at the tool tip temperature. For this experimental work different machining parameters were used depth of cut, speed
and feed rate, and work piece on the tool tip temperature during a machining ofEN8 material. To study the influence of each
parameter on tool tip temperature total 9 experiments were performed in order to find the minimum tool tip temperature. The
experiments were performed by varying one parameter while, the keep two parameter were kept constant. So the influence of tool
tip temperature on varying machining parameters is studied in this research work. The main objective of this study is to
investigate the effect of cutting parameters and to find out optimal conditions of spindle speed, feed, and depth of cut and work
piece material for achieving minimum temperature and to increase the quality of work peice material by reducing the temperature
using vegetable . In this experiment tool tip temperature measurement instrument is used to find the optimum parametric
conditions like spindle speed, feed and depth of cut on EN-8 material. The analysis reveals that spindle speed has major effect on
tool tip temperature while using Soya oil as lubricant.
Key Words: Tool tip temperature, spindle speed, feed rate and Depth of cut.
International Journal of Computational Engineering Research (IJCER) ijceronline
International Journal of Computational Engineering Research(IJCER) is an intentional online Journal in English monthly publishing journal. This Journal publish original research work that contributes significantly to further the scientific knowledge in engineering and Technology
Modeling and Analysis for Cutting Temperature in Turning of Aluminium 6063 Us...IOSR Journals
Deviation in machining process due to the temperature influence, cutting force, tool wear leads to
highly inferior quality of finished product, especially in high speed machining operations where product quality
and physical dimensions seems to be meticulous. Moreover, temperature is a significant noise parameter which
directly affects the cutting tool and work piece. Hence the aim of this project work is to study the machining
effect on 6063 Aluminium alloy at varies combinations of process parameters such as speed, feed rate and depth
of cut; and also to determine the effect of those parameters over the quality of finished product. A L27
Orthogonal Array (OA) based Design of Experiments (DOE) approach and Response Surface Methodology
(RSM) was used to analyse the machining effect on work material in this study. Using the practical data
obtained, a mathematical model was developed to predict the temperature influence and surface quality of
finished product. The ultimate goal of the study is to optimize the machining parameters for temperature
minimization in machining zone and improvement in surface finish.
Finite Element Analysis of Single Point Cutting ToolIJMER
In this project, temperature at tool-tip interface is determined, generated in high-speed machining operations. Specifically, three different analyses are comparing to an experimental measurement of temperature in a machining process at slow speed, medium speed and at high speed. In addition, three analyses are done of a High Speed Steel and of a Carbide Tip Tool machining process at three different cutting speeds, in order to compare to experimental results produced as part of this study. An investigation of heat generation in cutting tool is performed by varying cutting parameters at the suitable cutting tool geometry. The experimental results reveal that the main factors responsible for increasing cutting temperature are cutting speed (v), feed rate (f), and depth of cut (d), respectively. It is also determined that change in cutting speed and depth of cut has the maximum effect on increasing cutting temperature. Various researches have been undertaken in measuring the temperatures generated during cutting operations. Investigators made attempt to measure these cutting temperatures with various techniques during machining.
In this project, “Fluke 62 max IR thermometer” (Range -40 0C to 650 0C) is used for measuring temperature at tool-tip interface. Single point cutting tool has been solid modeled by using CAD Modeler Pro/E and FEA carried out by using ANSYS Workbench 14.5. Experimental work is done at “Khushi Engineering”, Nagpur.
By varying various parameters the effect of those on temperature are compared with the experimental results and FEA results. After comparison nearly 4% variation is found in between the results.
Finite Element Simulation Analysis of Three-Dimensional Cutting Process Based...IJRES Journal
Metal cutting process is a complicated process of plastic deformation and the finite element
method is used to simulate the cutting process. Chip is an important product of the cutting process, it has
important significance to analysis of it's formation process and influence factors in the research of material
processing performance, cutting tool optimization, etc..In this paper, the three-dimensional orthogonal and
oblique cutting models were established based on Johnson-Cook material constitutive models and damage laws.
The formation process of chip was analyzed according to the metal simulation cutting process, the influence of
cutting variables (Cutting depth, Cutting speed, Work piece thickness)on chip was analyzed based on the status
of chip.
Artificial Neural Network Modeling and Analysis of EN24 &EN36 Using CNC Milli...ijiert bestjournal
Metal cutting is one of the most significant manufa cturing processes in the area of material removal. It is Block it is defined metal cutting as the removal of metal chips from a work piece in order to obtain a finished product with de sired attributes of size,shape,and surface roughness.The imperative objective of the science o f metal cutting is the solution of practical problems associated with the efficient and precise removal of metal from work piece. It has been recognized that the reliable quantitative pred ictions of the various technological performance measures,preferably in the form of equ ations,are essential to develop optimization strategies for selecting cutting condi tions in process planning. In this thesis experiments has to be conducted to improve the surf ace finish quality of a work piece by using carbide tips. The type is bull nose tip. A se ries of experiments have to be done by varying the milling parameters spindle speed,feed rate and depth of cut and modeling is done by ANN. and Analysis is done by ANSYS.
Finite element modeling for maximum temperature in friction stir welding of a...eSAT Publishing House
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
Studies on material removal rate of al6061 while turning with coolant and wit...eSAT Journals
Abstract: Material Removal Rate (MRR) is one of the key attribute of machining process which influences productivity. In this work the effect of various turning process parameters on MRR produced on Al6061 (as cast condition) is investigated. Also, the effect of using coolant on MRR while turning is also determined. MRR is found to increase almost linearly with increase in feed rate. Increase in depth of cut and cutting speed is found to increase the MRR by 70.66 % and 16.36 % respectively. Keywords: Al6061, Material Removal Rate, Turning Process, Spindle Speed, Depth of Cut, ANOVA, Taguchi Method
Tank information system of kunigal taluk tumkur district, karanataka using ge...eSAT Publishing House
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology.
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology.
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
Root cause failure analysis of blanking device of strainer housing used in st...eSAT Publishing House
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology.
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
Finite Element Simulation and Experiment of Chip Formation Process during Hig...IDES Editor
As an advanced manufacturing technology which
has been developed rapidly in recent years, high speed
machining is widely applied in many industries. The chip
formation during high speed machining is a complicated
material deformation and removing process. In research area
of high speed machining, the prediction of chip morphology is
a hot and difficult topic. A finite element method based on the
software ABAOUS which involves Johnson-Cook material
model and fracture criterion was used to simulate the serrated
chip morphology and cutting force during high speed
machining of AISI 1045 hardened steel. The serrated chip
morphology and cutting force were observed and measured by
high speed machining experiment of AISI 1045 hardened steel.
The effects of rake angle on cutting force, sawtooth degree
and space between sawteeth were discussed. The investigation
indicates that the simulation results are consistent with the
experiments and this finite element simulation method
presented can be used to predict the chip morphology and
cutting force accurately during high speed machining of
hardened steel.
The quality of the machined piece and tool life are greatly influenced by determination of
maximum temperature of the cutting tool. Numerous researchers have approached to solve this problem
with experimental, analytical and numerical analysis. There is hardly a consensus on the basics principles
of the thermal problem in metal cutting, even though considerable research effort has been made on it. It is
exceedingly difficult to predict in a precise manner the performance of tool for the machining process. This
paper reviews work on the requirements for optimization of Tool wear so that its life could easily be
predicted
A Review on Experimental Investigation of Machining Parameters during CNC Mac...IJERA Editor
This review paper aims towards the optimization of CNC turning operation when used over an OHNS material.
The lathe machine was chosen because of its widespread availability and its ability to perform various tasks
without much change in its structure. Also using lathe machines is very cheap and hence it is beneficial from
economic point of view as well. The turning operation was specifically chosen because of the various
advantages that it offers. It can be used for machining a large variety of materials and it is cheaper than milling.
OHNS (Oil Hardened Non Shrinking) tool was chosen due to its hardness. These materials are used only for
dies so it was chosen so that its industrial usage could be exploited. To comprehend the usage, all the input and
output parameters that could affect the machining process, namely input parameters like feed, cutting
conditions, speed, etc. and output parameters like surface roughness, surface finish, material removal rate were
analyzed using the researches that had already been done on CNC turning. After careful study of a variety of
research papers on this topic, it was decided that several input as well as the output parameters would be
considered which included feed, depth of cut and cutting speed were taken as the input parameters whereas
Material Removal Rate (MRR) and surface finish were taken as the output parameters. From the results of the
research papers, it was concluded that feed, depth of cut and cutting speed could be chosen as input parameters
whereas MRR and surface finish would be the output parameters
Optimization of machining parameters on tool tip temperature by using vegetab...eSAT Journals
Abstract
In this research the experiments were performed by using vegetable oil to know the effect of different machining parameters on
tool tip temperature. The quality of work piece material is main contributing factor in these days which may be influence by heat
generated at the tool tip temperature. For this experimental work different machining parameters were used depth of cut, speed
and feed rate, and work piece on the tool tip temperature during a machining ofEN8 material. To study the influence of each
parameter on tool tip temperature total 9 experiments were performed in order to find the minimum tool tip temperature. The
experiments were performed by varying one parameter while, the keep two parameter were kept constant. So the influence of tool
tip temperature on varying machining parameters is studied in this research work. The main objective of this study is to
investigate the effect of cutting parameters and to find out optimal conditions of spindle speed, feed, and depth of cut and work
piece material for achieving minimum temperature and to increase the quality of work peice material by reducing the temperature
using vegetable . In this experiment tool tip temperature measurement instrument is used to find the optimum parametric
conditions like spindle speed, feed and depth of cut on EN-8 material. The analysis reveals that spindle speed has major effect on
tool tip temperature while using Soya oil as lubricant.
Key Words: Tool tip temperature, spindle speed, feed rate and Depth of cut.
International Journal of Computational Engineering Research (IJCER) ijceronline
International Journal of Computational Engineering Research(IJCER) is an intentional online Journal in English monthly publishing journal. This Journal publish original research work that contributes significantly to further the scientific knowledge in engineering and Technology
Modeling and Analysis for Cutting Temperature in Turning of Aluminium 6063 Us...IOSR Journals
Deviation in machining process due to the temperature influence, cutting force, tool wear leads to
highly inferior quality of finished product, especially in high speed machining operations where product quality
and physical dimensions seems to be meticulous. Moreover, temperature is a significant noise parameter which
directly affects the cutting tool and work piece. Hence the aim of this project work is to study the machining
effect on 6063 Aluminium alloy at varies combinations of process parameters such as speed, feed rate and depth
of cut; and also to determine the effect of those parameters over the quality of finished product. A L27
Orthogonal Array (OA) based Design of Experiments (DOE) approach and Response Surface Methodology
(RSM) was used to analyse the machining effect on work material in this study. Using the practical data
obtained, a mathematical model was developed to predict the temperature influence and surface quality of
finished product. The ultimate goal of the study is to optimize the machining parameters for temperature
minimization in machining zone and improvement in surface finish.
Finite Element Analysis of Single Point Cutting ToolIJMER
In this project, temperature at tool-tip interface is determined, generated in high-speed machining operations. Specifically, three different analyses are comparing to an experimental measurement of temperature in a machining process at slow speed, medium speed and at high speed. In addition, three analyses are done of a High Speed Steel and of a Carbide Tip Tool machining process at three different cutting speeds, in order to compare to experimental results produced as part of this study. An investigation of heat generation in cutting tool is performed by varying cutting parameters at the suitable cutting tool geometry. The experimental results reveal that the main factors responsible for increasing cutting temperature are cutting speed (v), feed rate (f), and depth of cut (d), respectively. It is also determined that change in cutting speed and depth of cut has the maximum effect on increasing cutting temperature. Various researches have been undertaken in measuring the temperatures generated during cutting operations. Investigators made attempt to measure these cutting temperatures with various techniques during machining.
In this project, “Fluke 62 max IR thermometer” (Range -40 0C to 650 0C) is used for measuring temperature at tool-tip interface. Single point cutting tool has been solid modeled by using CAD Modeler Pro/E and FEA carried out by using ANSYS Workbench 14.5. Experimental work is done at “Khushi Engineering”, Nagpur.
By varying various parameters the effect of those on temperature are compared with the experimental results and FEA results. After comparison nearly 4% variation is found in between the results.
Finite Element Simulation Analysis of Three-Dimensional Cutting Process Based...IJRES Journal
Metal cutting process is a complicated process of plastic deformation and the finite element
method is used to simulate the cutting process. Chip is an important product of the cutting process, it has
important significance to analysis of it's formation process and influence factors in the research of material
processing performance, cutting tool optimization, etc..In this paper, the three-dimensional orthogonal and
oblique cutting models were established based on Johnson-Cook material constitutive models and damage laws.
The formation process of chip was analyzed according to the metal simulation cutting process, the influence of
cutting variables (Cutting depth, Cutting speed, Work piece thickness)on chip was analyzed based on the status
of chip.
Artificial Neural Network Modeling and Analysis of EN24 &EN36 Using CNC Milli...ijiert bestjournal
Metal cutting is one of the most significant manufa cturing processes in the area of material removal. It is Block it is defined metal cutting as the removal of metal chips from a work piece in order to obtain a finished product with de sired attributes of size,shape,and surface roughness.The imperative objective of the science o f metal cutting is the solution of practical problems associated with the efficient and precise removal of metal from work piece. It has been recognized that the reliable quantitative pred ictions of the various technological performance measures,preferably in the form of equ ations,are essential to develop optimization strategies for selecting cutting condi tions in process planning. In this thesis experiments has to be conducted to improve the surf ace finish quality of a work piece by using carbide tips. The type is bull nose tip. A se ries of experiments have to be done by varying the milling parameters spindle speed,feed rate and depth of cut and modeling is done by ANN. and Analysis is done by ANSYS.
Finite element modeling for maximum temperature in friction stir welding of a...eSAT Publishing House
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
Studies on material removal rate of al6061 while turning with coolant and wit...eSAT Journals
Abstract: Material Removal Rate (MRR) is one of the key attribute of machining process which influences productivity. In this work the effect of various turning process parameters on MRR produced on Al6061 (as cast condition) is investigated. Also, the effect of using coolant on MRR while turning is also determined. MRR is found to increase almost linearly with increase in feed rate. Increase in depth of cut and cutting speed is found to increase the MRR by 70.66 % and 16.36 % respectively. Keywords: Al6061, Material Removal Rate, Turning Process, Spindle Speed, Depth of Cut, ANOVA, Taguchi Method
Tank information system of kunigal taluk tumkur district, karanataka using ge...eSAT Publishing House
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology.
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology.
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
Root cause failure analysis of blanking device of strainer housing used in st...eSAT Publishing House
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology.
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology.
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology.
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
Fpga based highly reliable fault tolerant approach for network on chip (noc)eSAT Publishing House
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
An enhanced adaptive scoring job scheduling algorithm with replication strate...eSAT Publishing House
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology.
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IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
Development of microcontroller based instrument for checking quality of edibl...eSAT Publishing House
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
NUMERICAL AND EXPERIMENTAL VALIDATION OF CHIP MORPHOLOGYIAEME Publication
The extensive research studies are used to divination the behavior of complex
Metal cutting processes. The cutting parameters such as speed, feed and force play
important role on conform chip morphology. The experimental techniques for
investigation the chip morphology is expensive and time consuming. To overcome
these difficulties Finite element modeling and simulation process are used as effective
tool to divination the effect of cutting variables. In the present study FEA simulation
process model is developed to divination the chip morphology and cutting forces in
turning of Al-6061 with WC tool. Johnson cook material models are considered for
visco-elastic material behavior. The obtained simulation process results are compared
with experimental process results
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Modeling and optimization of end milling machining processeSAT Journals
Abstract Generally in any manufacturing industry, a human process planner selects the machining parameters based on his expertise or from data handbooks; they do not represent the optimal values. The optimization process involves the optimal selection of machining parameters such as cutting speed, feed and depth of cut, subjected to practical constraints of surface finish, tool wear, dimensional accuracy and machine tool capabilities. Several researches have used different techniques in literature to optimize machining process by considering a machining problem as single objective optimization problem. However a machining problem should be treated as a multi objective problem as it involves two conflicting objectives: machining time and production cost. In such problems there cannot be single optimal solution. To get all optimal solutions, a multi objective optimization method called Non-dominated Sorting Genetic Algorithm (NSGA) is proposed in the project work. In the first part of the present work, mathematical relationships between input and output parameters have been developed by Response Surface Methodology (RSM). Consequently there have been solved to get the optimal values. The general second order composite rotatable design is used in planning and modeling the experiments. The experiments were conducted on the general purpose milling machine using a 60mm*60mm*40mm block (AISI 1040steel).In the second part a multi optimization algorithm called non dominated sorting genetic algorithm was used to retrieve all set of optimum values. In NASA, the non-dominated sorting procedure is used to bring forth the good points of correct population and stable subpopulations of good points are maintained by Niche method. The present work enables the industries to have the optimum values of the milling process variables and conducting the process can be automated based on optimal values. Index Terms: AISI 1040steel, Non-dominated Sorting Genetic Algorithm (NSGA), Optimization, Response Surface Methodology (RSM), and Multi Optimization Algorithm etc…
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology.
Conceptual design of laser assisted fixture for bending operationeSAT Publishing House
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
The quality of the machined piece and tool life are greatly influenced by determination of
maximum temperature of the cutting tool. Numerous researchers have approached to solve this problem
with experimental, analytical and numerical analysis. There is hardly a consensus on the basics principles
of the thermal problem in metal cutting, even though considerable research effort has been made on it. It is
exceedingly difficult to predict in a precise manner the performance of tool for the machining process. This
paper reviews work on the requirements for optimization of Tool wear so that its life could easily be
predicted.
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
Prediction of output Responses in Milling of Casted Aluminum by using ANNijiert bestjournal
The important goal in the modern industries is to m anufacture the products with lower cost and with hi gh quality in short span of time. There are two main p ractical problems that engineers face in a manufacturing process. The first is to determine th e values of process parameters that will yield the desired product quality (meet technical specificati ons) and the second is to maximize manufacturing system performance using the available resources. T he increase of customer needs for quality products (more precise tolerances and better product surface roughness) have driven the metal cutting process. The main objective of this project work is to study the effect of surface roughness and Material Removal R ate in a machining of cast aluminum on CNC milling mach ine with High Speed Steel cutting tool. The feasibility of implementation of design of experime nts (DOE),and Artificial Neural network in milling process is analyzed.
Optimization of crosspiece of washing machineeSAT Journals
Abstract The Optimization through FEA is new emerging field. Now a day’s providing product with less cost and with good functioning becomes necessary due to high competitions in market. Nowadays it is very necessary to shorten the development process of new components. Therefore tools are necessary that replace the natural evolution process by an automatic procedure. With today’s available resources the optimization approach is the best approach for industrial components which are having large number of design variables with more than one objective to satisfy. This paper includes optimization of crosspiece of washing machine by using FEA concept. One simple component is taken to correlate optimization FEA results with practical results. After validating simulation results of optimization, industrial component crosspiece of washing machine with drum assembly is considered for optimization. The material reduction objective is satisfied here by using simulation software tools like Optistruct, Hypermesh, Hyper view. The output shape from optistruct is converted into manufacturable part. Again simulation testing is performed for static loading. At last results before optimization and after optimization are compared for crosspiece.
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology.
Optimization of Cutting Rate for EN 1010 Low Alloy Steel on WEDM Using Respon...IJAEMSJORNAL
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Finite element analysis on temperature distribution in turning process using deform 3 d
1. IJRET: International Journal of Research in Engineering and Technology ISSN: 2319-1163
__________________________________________________________________________________________
Volume: 02 Issue: 05 | May-2013, Available @ http://www.ijret.org 901
FINITE ELEMENT ANALYSIS ON TEMPERATURE DISTRIBUTION IN
TURNING PROCESS USING DEFORM-3D
Yash R. Bhoyar1
, Asst. Prof. P. D. Kamble2
1
M. Tech 2nd year, 2
Assistant Professor, Department of Mechanical, Yeshwantrao Chavan College of Engineering,
Hingna Road, Nagpur, Maharashtra, India,
bhoyar.yash@gmail.com, pdk121180@yahoo.com
Abstract
The aim of this study is to create a finite element analysis simulation model in order to obtain solutions of the cutting forces, specific
cutting energy and adequate temperatures occurring at different points through the chip/tool contact region and the coating/substrate
boundary for a range of cutting tool materials and defined cutting conditions. Interfacial temperature in machining plays a major role
in tool wear and can also result in modifications to the properties of the work piece and tool materials. As there is a general move
towards dry machining, for environmental reasons, it is increasingly important to understand how machining temperature are affected
by the process variables involved (cutting speed, feed rate, tool geometry, etc.) and by other factors such as tool wear.
Index Terms: Turning Process, FEA, Analytical Modeling etc…
-----------------------------------------------------------------------***-----------------------------------------------------------------------
1. INTRODUCTION
The turning process is used widely in industry and has
countless applications. Traditionally, the process has been
used to reduce the diameter of cylindrical work piece, or to
change a work piece of non-circular cross-section. This is
done by rotating the work piece about this of the machine’s
spindle and removing the work piece material with the cutting
tool which is fed in the perpendicular direction. For the past
fifty years metal cutting researchers have developed many
modeling techniques including analytical techniques, slip-line
solutions, empirical approaches and finite element techniques.
In recent years, the finite element analysis has particularly
become the main tool for simulating metal cutting processes.
Finite element analysis are widely used for calculating the
stress, strain, strain-rate and temperature distributions in the
primary, secondary and tertiary sub-cutting zones. In
consequence, temperatures in the tool, chip and work piece, as
well as cutting forces, plastic deformation (shear angles and
chip thickness), chip formation and possibly its breaking can
be determined faster than using costly and time consuming
experiments. In this work, FEA based models are developed
that are able to predict the effect of various process variables
on the performance measures of interests such as cutting
forces, tool breakages, and surface accuracy.
1.1 The Turning Process
Turning is a very important machining process in which a
single-point cutting tool removes material from the surface of
a rotating cylindrical work piece. The cutting tool is feed
linearly in a direction parallel to the axis of rotation. Turning
is carried out on a lathe that provides the power to turn the
work piece at a given rotational speed and to feed the cutting
tool at a specified rate and depth of cut. Therefore, Five
cutting parameters, i.e. cutting speed, feed rate, and depth of
cut, tool geometry (nose radius) and cutting condition need to
be determined in a turning operation for optimize parameter.
1.2 Finite Element Analysis of Turning Process
Finite element analysis is a most useful and accurate approach
for the determination of field variables that is made possible
by advancements in computational and processing power of
computers and thus it is almost used for all the computer aided
design methodologies in recent years. Applications range from
deformation and stress analysis to field analysis of heat flux,
fluid flow, magnetic flux, seepage and other flow problem. In
this method of analysis, a complex region defining a
continuum is discredited into simple geometric shapes called
finite elements. The Present work is also based on the
application of finite element for thermal analysis of single
point cutting tool for turning operation. Once the model
developed for determination of temperature field for single
point cutting tool, it can also be implemented for other
multipoint processes like drilling, milling or grinding also.
Modeling 3D cutting process using finite element techniques
is an area of ongoing research activity due to significant cost
savings and offers insights into the process which are not
easily measured in experiments,. In particular heat transfer and
the modeling of cutting process requires careful consideration
in any modeling activity. This paper presents approaches for
modeling the turning process for EN-24 type of steel. In this
study, a Finite Element Analysis software Deform 3D is used
to study the effects of cutting speed, feed rate, and type of
2. IJRET: International Journal of Research in Engineering and Technology ISSN: 2319-1163
__________________________________________________________________________________________
Volume: 02 Issue: 05 | May-2013, Available @ http://www.ijret.org 902
alloy steel in temperature behavior. The work-piece is
modeled as Elastic-plastic material to take thermal, elastic,
plastic effect. Work-piece is represented by a liner model with
different length for each condition.
The short material length was chosen to save computational
time without compromising the model integrity as heat
generation in machining is confined in small areas around the
cutting zone. The work-piece shape is constructed by the
DEFORM machining module, and includes geometry created
by a previous tool pass, including appropriate depth of cut and
nose radius details. An unstructured tetrahedral finite element
mesh was generated using DEFORM’s automatic mesh
generation system. Re-meshing parameters, including
minimum element size, and parameters for adaptive mesh
definition are set within the system. For these Procedures of
the simulations, a minimum element size of 0.25 of the fed
rate was specified. The total number of elements was 100000
to 130000 depending upon work-piece size. The Lagrangian
calculation embeds a computational mesh in the material
domain and solves for the position of the mesh at discrete
points in time. An incremental Lagrangian formulation with an
implicit integration method designed for large deformation
simulations is used to simulate the cutting process. The solver
used was the sparse matrix with a direct integration method,
because the conjugate-gradient offers an improved
computational speed but less stability in convergence. [10]
The FEA simulation of turning process with the help of
DEFORM 3D is show in Figure.
Fig.-1: Initial temperature distribution during chip formation
Fig.-2: Initial mesh and tool indentation
1.3 Temperature Measurement
The cutting speeds used in experimentation made response
times of the temperature measurement devices an important
criterion. The temperature measurement devices also had to be
robust and have a wide measurement range. The Pyrometers is
technical advances have made it possible today to measure not
only high temperatures but also temperatures far below
freezing point from a distance and without making contact
with the object to be measured.
Pyrometer Types:
• Spectral band pyrometers
• Total band pyrometers
• Ratio Pyrometers (2 color pyrometers)
• Disappearing filament optical pyrometer (portable)
• Infrared pyrometer
• Laser pyrometer
We use Optical Infrared Pyrometer, which work on very
sophisticated mechanism. This thermal device detect
temperature of an object by reckoning the emitted, reflected
and transmitted energy by means of optical sensors &
detectors and show temperature reading on display panel. The
temperature Range is 0º to 520º C as shown in figure.
Fig.-3: Optical Infrared Pyrometer
3. IJRET: International Journal of Research in Engineering and Technology ISSN: 2319-1163
__________________________________________________________________________________________
Volume: 02 Issue: 05 | May-2013, Available @ http://www.ijret.org 903
2. LITERATURE REVIEW
A Review of literature describes to study of the Temperature
distribution of turning process with the help of finite element
analysis.
Typical approaches for numerical modeling of metal cutting
processes is Lagrangian and Eulerian techniques, as well as a
combination of both called an arbitrary Lagrangian–Eulerian
formulation [2, 6]. It should be noticed that all these methods
are mathematically equivalent. The major feature of
Lagrangian formulation used in this study is that the mesh is
attached to the work piece.
Also, the finite element analysis were performed by Johnson-
Cook’s constitutive equation with three different sets of
material constants (found by the application of several
methods) is implemented in the FE model to study the
behavior of Ti6Al4V alloy during the machining process in
conventional and high speed regimes [4]. Demand for higher
productivity and good quality for machining parts has
encourage many researchers to study the effects of machining
parameters using FEM simulation using either two or three
dimensions version [5].
Asmaa A. kawi [10], Finite element method is a successful
technique to perform analysis to estimate cutting temperatures,
a possibility of developing temperature forms adequately
representing metal cutting temperature as a Polynomial
models of third, fourth and fifth degree with time that give
steady state temperature and for the four alloys steel used and
different operation conditions. All alloys have a sever
increasing temperature with increasing feed rate, while it looks
less sharp with increasing cutting speed .Also the ratio of the
number of nodes have maximum temperature for any
operating conditions and any alloy used with respect to the
total number of nodes is less than 1%.
Mofid Mahdi, Liangchi Zhang [11], this study considered the
chip breaking and developed a 2D cutting force model with
the finite element method. The variation of the cutting force
was investigated carefully against both the cutting condition
and the anisotropy of the material with the following
development: (a) a constitutive model of a homogeneous
anisotropic elastic material under plane deformation; (b) a
failure model of the work material based on the Tsai Hill
criterion; (c) a contact model of the mechanisms of the cutting
process. A comparison with experimental measurements
showed that the constitutive model leads to a reasonable
prediction.
Tugrul Ozel, Taylan Altan [13], It shows a methodology to
determine simultaneously (a) the flow stress at high
deformation rates and temperatures that are encountered in the
cutting zone, and (b) the friction at the chip–tool interface.
This information is necessary to simulate high-speed
machining using FEA based programs. A flow stress model
based on process dependent parameters such as strain, strain-
rate and temperature was used together with a friction model
based on shear flow stress of the workpiece at the chip–tool
interface. High-speed cutting experiments and process
simulations were utilized to determine the unknown
parameters in flow stress and friction models.
J.C.Outeiro,J.C.Pina, R.M’Saoubi, F.Pusavec,I.S. Jawahir
[14], This study presents the influence of cutting process
parameters on machining performance and surface integrity
generated during dry turning of Inconel 718 and austenitic
stainless steel AISI 316L with coated and uncoated carbide
tools. A three-dimensional Finite Element Model was also
developed and the predicted results were compared with those
measured.
3. ANALYTICAL MODELING
3.1 Heat Balance
In order to solve the problem with finite element method
(FEM) using Deform-3D, analytical solution of the problem
was reviewed by choosing each element as a control volume.
From the first law of thermodynamics, the rate of difference
between thermal and mechanical energy entering and exiting
the control volume summing to the rate of heat generation is
equal to the rate f oenergy stored within the control volume.
This principal can be written as
Ein – Eout + Egenerated = Estored (1)
3.2 Heat Conduction
The rate of heat conduction to the control volume with the
dimensions of dx , dy and dz from x , y and z directions, are
called Qx & , Qy & and Qz & , respectively. The rate of heat
conduction in three directions is defined as
(2)
Here, k is the thermal conductivity and A is the area of the
surface that is exposed to this heat conduction.
3.3 Heat Convection
Another way of heat transfer is convection from the system to
the surrounding air; the heat convection rate is directed from
the control volume to the surrounding air which can be written
as following.
4. IJRET: International Journal of Research in Engineering and Technology ISSN: 2319-1163
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Volume: 02 Issue: 05 | May-2013, Available @ http://www.ijret.org 904
conv = ha A ( T Tᴔ ) (3)
Here, ha is the convection coefficient between the element and
the ambient air flowing around. The temperature of ambient
air is considered equal to the room temperature; therefore,
room temperature is boundary condition. Some elements are
not in contact with air so this term becomes zero for them.
3.4 Heat Generation
The amount of generated heat depends on heat generation rate
per control volume unit
E generated =q.dx.dy.dz (4)
The values of generated heat are obtained from the force and
velocity factors along shear and friction dimensions, as can be
seen in following.
Q = Fs Vs = (5)
Qf =Ff .Vc = (6)
In these equations, h is the uncut chip thickness which
corresponds to feed rate in turning; V is the cutting velocity; τ
is the shear flow stress; , and are the normal rake
angle, normal friction angle and normal shear angle,
respectively. The values of generated heat are per unit of cut;
therefore, we can achieve the real values with multiplying
them by depth of cut.
3.5 Heat Stored
The amount of heat stored within the control volume depends
on volume, density ρ, specific heat capacity C, and the rate of
temperature change in the control volume.
Estored = ρ. C dx.dy.dz (7)
It is assumed that heat flows from all surrounding objects and
enters to the control volume; therefore, the heat balance
equation can written as follow.
Qx+ Qy+ Qz + Qconv+ Qdxdydz = ρ C dxdydz (8)
In (8), Q is defined as the following term.
Q = qs + q f (9)
3.6 Discretizition Of Heat Equation By Explicit
Method
The problem must be discredited in time. The integer p is
introduced for this purpose, where t = pt and the finite
difference approximate to the time derivative in equation is
expressed as
=
=
= (10)
The superscript p denotes the time dependence of T; the time
derivative is expressed in terms of temperature difference
between the new (p +1) and previous (p) times.
In the explicit method of solution, these temperatures are
evaluated at the previous (p) time. Hence, Eq. 10 is considered
to be a forward difference approximation to the time
derivative. The accuracy of the finite difference solution may
be improved by decreasing the values of nodal dimension and
t.
An undesirable aspect of the explicit method is that it is not
unconditionally stable. In order to prevent the explicit method
from becoming unstable, the prescribed value of Dt must be
maintained below a certain limit which depends on element
dimensions and other parameters of the system.
3.7 Finite Difference Equation for Tool
In this section, after meshing of the tool, a partial differential
equation is derived for each element in this grid. Notice that in
the selection of the element numbers, both accuracy and time
are of great importance. In the present paper, the optimum
element number with proper precision is used for temperature
estimation. Differential equation for one type of the elements
is as the following.
kA’ +kA’’ + kA’’’ + h A (T- ) = CVρ
(11)
Here, it is assumed that element dimensions are Dx = Dy =
Dz; hence, A' , A" and A'" are equal surfaces, A = 3l2/4, A" =
l2/4, V = l3/8; Substituting these terms in (11) in a small time
interval, the following equation is obtained.
5. IJRET: International Journal of Research in Engineering and Technology ISSN: 2319-1163
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Volume: 02 Issue: 05 | May-2013, Available @ http://www.ijret.org 905
( ) +
+ =
(12)
By solving the nodal temperature of the new ( p +1) time, the
following is achieved.
+ q + ( ) ( ) (13)
Here, some parameters are defined.
F0 = (14)
Bi = (15)
Fo is Fourier number and Bi is Biot number, and finally we
have
+( )
4. RESULT
The temperature signals were measured by an immobile,
wholly digital and fast compact pyrometer for a calibrated
temperature range of -3 to +520 degrees centigrade. The laser
pilot lights direct the pyrometer to the measuring position. The
size of the measurement spot was 0.3 mm, which
corresponded to a distance to the measurement surface of
0.2m.
By Several experiments was performed in dry condition, the
maximum temperature of position A1 was exceed up to 240
0C near cutting edge was observed from the optimized
parameter. Similarly the temperature was decreases as far
from the maximum temperature were occur position A1, was
observed about 190 0C at A2 and 150 0C at A3.
Fig.-4: Points traced for measuring temperature distribution
The Simulation of Temperature distribution in Deform-3D is
perform by using Optimized Parameter as follows,
Speed – 158 m/min
Feed - 0.2 mm/rev
DOC - 2 mm
NR - 1 mm
Condition – Dry
By solving analysis on Deform-3D we can find temperature
distribution at any position using point tracking method in
Deform-3D, fig.-6 shows the comparison of temperature
results between experiments and simulation.
Fig.-5: results of Experiments and Simulation
CONCLUSIONS
The following conclusions could be drawn from the results of
present study:
1) Finite element method using DEFORM 3D program
is found to be a successful technique to perform trend
analysis to estimate cutting temperatures in metal
cutting with respect to various combinations of design
variables (metal cutting speed, feed rate and depth of
cut).
6. IJRET: International Journal of Research in Engineering and Technology ISSN: 2319-1163
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Volume: 02 Issue: 05 | May-2013, Available @ http://www.ijret.org 906
2) In consequence, the maximum interface temperature
exists in the vicinity of the cutting edge i.e. in the first
part of the tool-chip contact.
3) Increased cutting speeds (Vc) resulted in decreased
cutting tool forces and machined surface
temperatures.
4) Tool wear resulted in increased cutting tool forces and
machined surface temperature.
5) Force has been found to be an important variable in
the generation of surface temperature.
6) Thus, it is possible to increase machine utilization and
decrease production cost in an automated
Manufacturing environment.
7) The formation of built-up layers in metal cutting
processes is very common with a variety of layers
formed having different compositions and
effectiveness in reducing cutting tool wear.
ACKNOWLEDGMENTS
I express my sincere gratitude to my guide, Prof. P. D.
Kamble, Asst. Professor, Mechanical Department,
Yeshwantrao Chavan College of Engineering for his valuable
guidance, proper advice, and careful reviews of my work at all
stages, and their highly appreciated instruction and constant
encouragement during the course of my work on this paper.
I am highly thankful to Prof. B. D. Deshmukh, Professor and
H.O.D., Mechanical Department, Yeshwantrao Chavan
College of Engineering for his expert advice, technical
suggestions and moral support during in this work.
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