This document summarizes a study that used finite element analysis to simulate machining of Inconel 718, a nickel-based superalloy. Orthogonal cutting experiments were conducted with cutting speeds of 50 m/min and a feed rate of 0.1 mm/rev. The Johnson-Cook constitutive model was used to represent the material's flow behavior. The results showed that chip segmentation did not occur at low cutting speeds and residual stresses were highest near the machined surface and lowest near the uncut surface and deformed chip. Plastic strain was highest in the primary shear zone and lowest at the free end of the chip.
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
Surface Topology Evaluation of P20 Steel by Multipass Cutting Strategy in Wir...IJERA Editor
Wire EDM process eliminates the work materials by a series of electrical sparks between the workpiece and wire electrode. These sparks creates craters and burs on the machined surface. Machined surface with poor integrity is a major disadvantage of WEDM. This work presents the investigation on multi-pass cutting operation (single rough cut followed by multi trim cuts) in wire electrical discharge machining (WEDM) of p20 steel. Trim cuts were performed using Taguchi’s design of experiment method to investigate the influence of discharge current (Ip), pulse-on time (Ton), pulse-off time, servo voltage and number of trim cuts on two performance characteristics namely cutting rate and surface roughness (SR).Experiments were performed using 0.25mm brass wire. Result shows that the surface finish improves significantly in trim cutting operation.
Multi-Objective Optimization ( Surface Roughness & Material Removal Rate) of ...IJERA Editor
The present study applied Taguchi method through a case study in straight turning of AISI 202 stainless steel bar on CNC Machine ( Mfd by ACE DESIGNERS) using Titanium Carbide tool for the optimization of Material removal rate, Surface Roughness and tool wear process parameter.The study aimed at evaluating the best process environment which could simultaneously satisfy requirements of both quality as well as productivity with special emphasis on maximizing material removal rate and minimizing surface roughness and tool flank wear at various combination of cutting speed, feed, depth of cut. The predicted optimal setting ensured maximum MRR and minimum surface roughness and tool wear. Since optimum material removal rate is desired, so higher the better criteria of Taguchi signal to noise ratio is used for MRR – SNs = -10 log(Sy2/n) For surface roughness and tool wear – SNL = -10 log(S(1/y2)/n) The results have been verified with the help of S/N Ratios calculation and various graphs have been plotted to show the below mentioned observations.
a) MRR first increases with increase in cutting speed and then decreases.
b) With the increase in feed, MRR increases.
c) With the increase in depth of cut, MRR first increases and then decreases.
d) With the increase in cutting speed, Surface Roughness first decreases and then increases.
e) With the increase in feed, Surface Roughness increases.
f) With the increase in depth of cut, Surface Roughness first increases and then decreases.
International Journal of Computational Engineering Research(IJCER)ijceronline
International Journal of Computational Engineering Research (IJCER) is dedicated to protecting personal information and will make every reasonable effort to handle collected information appropriately. All information collected, as well as related requests, will be handled as carefully and efficiently as possible in accordance with IJCER standards for integrity and objectivity
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.
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.
This document describes the development of a 3D finite element model to simulate micro cutting of ferritic-pearlitic carbon steels. It first characterizes the microstructure and constitutive behavior of ferrite and pearlite phases in carbon steels. It then develops a 3D two-phase FE material model for steel C45 based on a representative volume element and Voronoi tessellation. The model incorporates the volume fractions, grain sizes and constitutive models of the two phases. Finally, it validates the model by simulating micro drilling and milling tests and predicting size effects in micro cutting of the multiphase steel.
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.
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
Surface Topology Evaluation of P20 Steel by Multipass Cutting Strategy in Wir...IJERA Editor
Wire EDM process eliminates the work materials by a series of electrical sparks between the workpiece and wire electrode. These sparks creates craters and burs on the machined surface. Machined surface with poor integrity is a major disadvantage of WEDM. This work presents the investigation on multi-pass cutting operation (single rough cut followed by multi trim cuts) in wire electrical discharge machining (WEDM) of p20 steel. Trim cuts were performed using Taguchi’s design of experiment method to investigate the influence of discharge current (Ip), pulse-on time (Ton), pulse-off time, servo voltage and number of trim cuts on two performance characteristics namely cutting rate and surface roughness (SR).Experiments were performed using 0.25mm brass wire. Result shows that the surface finish improves significantly in trim cutting operation.
Multi-Objective Optimization ( Surface Roughness & Material Removal Rate) of ...IJERA Editor
The present study applied Taguchi method through a case study in straight turning of AISI 202 stainless steel bar on CNC Machine ( Mfd by ACE DESIGNERS) using Titanium Carbide tool for the optimization of Material removal rate, Surface Roughness and tool wear process parameter.The study aimed at evaluating the best process environment which could simultaneously satisfy requirements of both quality as well as productivity with special emphasis on maximizing material removal rate and minimizing surface roughness and tool flank wear at various combination of cutting speed, feed, depth of cut. The predicted optimal setting ensured maximum MRR and minimum surface roughness and tool wear. Since optimum material removal rate is desired, so higher the better criteria of Taguchi signal to noise ratio is used for MRR – SNs = -10 log(Sy2/n) For surface roughness and tool wear – SNL = -10 log(S(1/y2)/n) The results have been verified with the help of S/N Ratios calculation and various graphs have been plotted to show the below mentioned observations.
a) MRR first increases with increase in cutting speed and then decreases.
b) With the increase in feed, MRR increases.
c) With the increase in depth of cut, MRR first increases and then decreases.
d) With the increase in cutting speed, Surface Roughness first decreases and then increases.
e) With the increase in feed, Surface Roughness increases.
f) With the increase in depth of cut, Surface Roughness first increases and then decreases.
International Journal of Computational Engineering Research(IJCER)ijceronline
International Journal of Computational Engineering Research (IJCER) is dedicated to protecting personal information and will make every reasonable effort to handle collected information appropriately. All information collected, as well as related requests, will be handled as carefully and efficiently as possible in accordance with IJCER standards for integrity and objectivity
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.
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.
This document describes the development of a 3D finite element model to simulate micro cutting of ferritic-pearlitic carbon steels. It first characterizes the microstructure and constitutive behavior of ferrite and pearlite phases in carbon steels. It then develops a 3D two-phase FE material model for steel C45 based on a representative volume element and Voronoi tessellation. The model incorporates the volume fractions, grain sizes and constitutive models of the two phases. Finally, it validates the model by simulating micro drilling and milling tests and predicting size effects in micro cutting of the multiphase steel.
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.
Investigation of Process Parameters for Optimization of Surface Roughness in ...IJERA Editor
Surface roughness has significant effect on functionality and service life of components. If surface roughness is properly controlled then, performance of the component enhances in operational applications. Surface roughness becomes key concern when intricate profiles and shapes are required to be manufactured in components. The objective of the paper is to bring up an adequate surface roughness in finish cut by optimizing process variables. If initial surface form is obtained by proper control of machining parameters then additional finishing efforts and lead time reduce a lot. In the industrial tool room survey availability of machining data is prime concern in terms of tuned process parameter for precision machining. Optimization of process parameters is essential in order to arrest surface roughness and thereby improve surface textures. Experimental investigations are performed to study the effect of pulse current, pulse on time and gap voltage on response of surface roughness, in case of ram EDM. Design of experimentation (DOE) and ANOVA are carried out for optimization of process parameters, within work interval of finish cut machining
IRJET-Optimization of Machining Parameters Affecting Metal Removal Rate of Al...IRJET Journal
The document discusses optimizing machining parameters to increase the metal removal rate in dry end milling of aluminum alloy 6082. The machining parameters investigated are spindle speed, feed rate, and depth of cut. Experiments were performed using a Taguchi design of experiments with the parameters tested at three levels. The experimental data was analyzed using Minitab software to identify the most significant factor affecting metal removal rate. The goal is to determine the optimal settings of the machining parameters to maximize productivity during end milling of aluminum alloy 6082.
The document summarizes a study that investigated the effects of cutting speed, feed rate, and depth of cut on surface roughness and power consumption when turning 6063 aluminum alloy reinforced with 5% and 10% titanium carbide composites. 27 experimental runs were conducted using a full factorial design varying the machining parameters at three levels. Analysis of variance was used to determine the percentage contribution of each parameter on surface roughness and power consumption. The results showed that feed rate is the most significant parameter affecting surface roughness, while cutting speed has the greatest effect on power consumption. The conclusions provide insights on optimizing the machining parameters to minimize surface roughness and power usage during machining of these metal matrix composites.
This document summarizes a study that used finite element modeling to simulate the hot rolling process and investigate the effects of various process parameters. The study developed a 3D finite element model of the hot rolling process using Abaqus software. It then analyzed how changes in parameters like slab thickness, rolling speed, roll diameter, thickness reduction, and temperature affect outcomes like temperature distribution, stress, strain, and roll force. The model was validated by comparing its predictions to theoretical results from previous studies. The results showed that increasing rolling speed, roll diameter, or thickness reduction increased roll force, while increasing temperature decreased roll force. Higher speeds also decreased minimum slab surface temperature.
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.
To analyses the effects of turning parameters on material removal rate of ais...eSAT Journals
Abstract This experimental investigation analyses the influence of cutting conditions on material removal rate (MRR) during turning of AISI 4041 die alloy steel. Analysis of variance (ANOVA) is employed to investigate the influence of cutting speed, feed rate, and depth of cut on material removal rate (MRR). Conducting the experiments by varying the parameters of turning like cutting speed from 100 m/min to 300 m/min, feed 0.02 mm/rev to 0.06 mm/rev, and depth of cut from 0.2 mm to 0.7 mm are studied in details according to Taguhi's design of experiments. At last results are analyzed using Taguchi, ANOVA and parametric optimization is done for maximum material removal rate (MRR). From the experimentation, it is concluded that for turning of AISI 4041 die alloy steel optimum machining condition for higher material removal rate (MRR) with cutting speed (300 m/min), feed rate (0.06 mm/rev), and depth of cut (0.2 mm). Index Terms: ANOVA, MRR, Taguch.
This document experimentally investigates and optimizes the micro drilling process parameters of austenitic stainless steel sheets using the Taguchi design of experiments approach. 27 experiments were conducted using a mini drilling machine to drill 0.5mm holes with varying spindle speed, feed rate, and point angle. The material removal rate was evaluated. Analysis found that feed rate had the greatest influence on material removal rate, and the optimal parameters were a spindle speed of 2000rpm, feed rate of 0.02mm, and point angle of 1260. These parameters produced the highest material removal rate and minimum tool wear during micro drilling of austenitic stainless steel sheets.
Optimization of tungsten inert gas welding on 6063 aluminum alloy on taguchi ...RSIS International
In this paper, the Taguchi method is used for the
Optimization of Tungsten Inert Gas Welding on 6063
Aluminum Alloy. The Taguchi method L27 is used to
optimize the pulsed TIG welding process parameters of 6063
aluminum alloy weldments for maximizing the mechanical
properties. Analysis of Variance is used to find the impact of
individual factors. Then the optimal parameters of the TIG
welding process is determined and the experimental results
illustrate the proposed approach.
AISI 304 stainless steel have a wide range of applications in the industrial field. The need for
machining AISI 304 SS has not been eliminated fully. The electrode wear rate (EWR) is an
important aspect during electrical discharge machining (EDM). In this investigation an attempt has
been made to assess the factors influencing electrode wear rate on the machining of AISI 304 SS.
Design of experiments (full factorial design) concept has been used for experimentation. The
machining experiments were conducted on a die sinking EDM machine using two levels of factors.
The factors considered were electrode shape, pulse current, pulse on time and pulse off time. A
procedure has been developed to assess and optimize the chosen factors to attain minimum electrode
wear rate by incorporating: (i) response table and response graph; (ii) normal probability plot; (iii)
interaction graphs; (iv) analysis of variance (ANOVA) technique. The results indicated that
electrode shape is a factor, which has greater influence on EWR, followed by pulse off time. Also the
determined optimal conditions really reduce the EWR on the machining of AISI 304 SS within the
ranges of parameters studied.
Parametric Optimization on MIG Welded EN8 Material Joints by using Taguchi Me...ijsrd.com
Welding is a manufacturing process, which is carried out for joining of metals. By MIG Welding it is possible to weld in all positions. Optimization of the parameter will be carried out by Taguchi method. We will use EN-8 material which is more use in Automobile parts. EN8 plate with dimensions 250mm x 125mm x 6mm with V- Groove 650.Where the input parameters are welding current, Wire feed and gas flow rate and output parameters are tensile strength and Hardness.
IRJET- Review Paper Optimizationof MachiningParametersbyusing of Taguchi'...IRJET Journal
This document summarizes an experimental study that used the Taguchi method to optimize machining parameters for turning AA6063 alloy steel. The study aimed to maximize the material removal rate (MRR) by investigating the effects of cutting speed, depth of cut, and feed rate. A number of turning experiments were conducted using an L9 orthogonal array with different combinations of the machining parameters. Analysis of the experimental results found that feed rate had the greatest influence on MRR, followed by depth of cut. The Taguchi method was effective for determining the optimal machining parameters for maximizing the material removal rate during turning of AA6063 alloy steel.
Optimization of cutting parameters on mild steel with hss & cemented carbide ...eSAT Publishing House
This document presents a study on optimizing cutting parameters for machining mild steel with high speed steel and cemented carbide tools using artificial neural networks. Experimental results were used to train an ANN model to predict surface roughness. Optimum cutting conditions were determined, with speeds of 729 rpm and 702 rpm, feeds of 0.056 mm/rev and 0.051 mm/rev, and depths of cut of 0.44 mm and 0.416 mm yielding predicted surface roughnesses of 1.73 microns and 2.74 microns for HSS and cemented carbide tools respectively. The ANN approach achieved prediction accuracies of 92% and 93% compared to experimental values.
This paper focus on monitoring of surface roughness and cutting forces while
machining on two different grade stainless steels under dry and mist conditions.
Stainless steels like AISI 304 and AISI 316L are considered for study. Process
variables like workpiece speed, tool feed and depth of cut are taken for
experimentation on CNC lathe. Responses like surface roughness, power consumption
and cutting forces are predicted while machining on the two different stainless grades
under dry and mist. Taguchi design of experiments is considered for experimental
design. Signal-to-noise ratio of the responses are used for determining individual
optimization, while Analysis of Variance is used for knowing significant effect of
process variables over the generated responses. This paper shows novelty of using
power consumption for calculating cutting forces and also comparisons of two
different stainless steel grades simultaneously under dry and mist conditions. In
addition, comparison of AISI 304 material with two different diameters is also studied
IJERA (International journal of Engineering Research and Applications) is International online, ... peer reviewed journal. For more detail or submit your article, please visit www.ijera.com
Finite element modeling of the broaching process of inconel718Phuong Dx
This document summarizes a study that used finite element modeling to simulate the broaching process of Inconel718. The study compared simulation results to experimental data and found good agreement for cutting forces. Models for cutting forces as functions of cutting parameters were developed based on simulation results. Additionally, the effects of rake angle and rising per tooth on chip curling and gullet area ratios were examined. Increasing rake angle or decreasing rising per tooth decreased chip curling diameter. Simulated chip curling diameters and area ratios were larger than recommended design values, suggesting gullet dimensions could be increased to improve chip flow.
The document describes a study that uses finite element analysis and Taguchi's method to optimize the preform shape of a connecting rod forging. The goal is to minimize forging load and produce defect-free forgings. Finite element software was used to simulate hot forging of the connecting rod under different preform design parameters, including flash thickness, width, and radii. Taguchi's method was then applied to design parameter combinations to determine the most influential parameters. Through several optimization iterations, the optimal preform shape that gave minimum forging load and complete die filling was obtained. The approach aims to reduce design time and costs compared to traditional trial and error methods.
The document presents a study that aims to optimize welding variables and predict weld bead geometry in gas metal arc welding (GMAW) process. Experiments were conducted using a central composite design to study the relationship between input process parameters (current, speed, angle, distance, pinch) and output parameters (bead width, height, depth, dilution). Mathematical models were developed using regression analysis. A neural network was then used to predict welding outputs, and a simulated annealing algorithm was applied to optimize the process parameters to achieve optimum dilution.
Optimization of Process Parameters in Turning Operation of AISI-1016 Alloy St...IOSR Journals
This paper investigates the parameters affecting the roughness of surfaces produced in the turning
process for the material AISI-1016 Steel. Design of experiments was conducted for the analysis of the influence
of the turning parameters such as cutting speed, feed rate and depth of cut on the surface roughness. The
results of the machining experiments for AISI-1016 were used to characterize the main factors affecting
surface roughness by the Analysis of Variance (ANOVA) method. The feed rate was found to be the most
significant parameter influencing the surface roughness in the turning process.
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
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 Paper Presentation which won the award for 'Best Paper' at 5th International Conference on Industrial Engineering 2019, S.V.N.I.T., Surat, India. Presentation elaborates research carried out for the same paper published in the conference.
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.
Investigation of Process Parameters for Optimization of Surface Roughness in ...IJERA Editor
Surface roughness has significant effect on functionality and service life of components. If surface roughness is properly controlled then, performance of the component enhances in operational applications. Surface roughness becomes key concern when intricate profiles and shapes are required to be manufactured in components. The objective of the paper is to bring up an adequate surface roughness in finish cut by optimizing process variables. If initial surface form is obtained by proper control of machining parameters then additional finishing efforts and lead time reduce a lot. In the industrial tool room survey availability of machining data is prime concern in terms of tuned process parameter for precision machining. Optimization of process parameters is essential in order to arrest surface roughness and thereby improve surface textures. Experimental investigations are performed to study the effect of pulse current, pulse on time and gap voltage on response of surface roughness, in case of ram EDM. Design of experimentation (DOE) and ANOVA are carried out for optimization of process parameters, within work interval of finish cut machining
IRJET-Optimization of Machining Parameters Affecting Metal Removal Rate of Al...IRJET Journal
The document discusses optimizing machining parameters to increase the metal removal rate in dry end milling of aluminum alloy 6082. The machining parameters investigated are spindle speed, feed rate, and depth of cut. Experiments were performed using a Taguchi design of experiments with the parameters tested at three levels. The experimental data was analyzed using Minitab software to identify the most significant factor affecting metal removal rate. The goal is to determine the optimal settings of the machining parameters to maximize productivity during end milling of aluminum alloy 6082.
The document summarizes a study that investigated the effects of cutting speed, feed rate, and depth of cut on surface roughness and power consumption when turning 6063 aluminum alloy reinforced with 5% and 10% titanium carbide composites. 27 experimental runs were conducted using a full factorial design varying the machining parameters at three levels. Analysis of variance was used to determine the percentage contribution of each parameter on surface roughness and power consumption. The results showed that feed rate is the most significant parameter affecting surface roughness, while cutting speed has the greatest effect on power consumption. The conclusions provide insights on optimizing the machining parameters to minimize surface roughness and power usage during machining of these metal matrix composites.
This document summarizes a study that used finite element modeling to simulate the hot rolling process and investigate the effects of various process parameters. The study developed a 3D finite element model of the hot rolling process using Abaqus software. It then analyzed how changes in parameters like slab thickness, rolling speed, roll diameter, thickness reduction, and temperature affect outcomes like temperature distribution, stress, strain, and roll force. The model was validated by comparing its predictions to theoretical results from previous studies. The results showed that increasing rolling speed, roll diameter, or thickness reduction increased roll force, while increasing temperature decreased roll force. Higher speeds also decreased minimum slab surface temperature.
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.
To analyses the effects of turning parameters on material removal rate of ais...eSAT Journals
Abstract This experimental investigation analyses the influence of cutting conditions on material removal rate (MRR) during turning of AISI 4041 die alloy steel. Analysis of variance (ANOVA) is employed to investigate the influence of cutting speed, feed rate, and depth of cut on material removal rate (MRR). Conducting the experiments by varying the parameters of turning like cutting speed from 100 m/min to 300 m/min, feed 0.02 mm/rev to 0.06 mm/rev, and depth of cut from 0.2 mm to 0.7 mm are studied in details according to Taguhi's design of experiments. At last results are analyzed using Taguchi, ANOVA and parametric optimization is done for maximum material removal rate (MRR). From the experimentation, it is concluded that for turning of AISI 4041 die alloy steel optimum machining condition for higher material removal rate (MRR) with cutting speed (300 m/min), feed rate (0.06 mm/rev), and depth of cut (0.2 mm). Index Terms: ANOVA, MRR, Taguch.
This document experimentally investigates and optimizes the micro drilling process parameters of austenitic stainless steel sheets using the Taguchi design of experiments approach. 27 experiments were conducted using a mini drilling machine to drill 0.5mm holes with varying spindle speed, feed rate, and point angle. The material removal rate was evaluated. Analysis found that feed rate had the greatest influence on material removal rate, and the optimal parameters were a spindle speed of 2000rpm, feed rate of 0.02mm, and point angle of 1260. These parameters produced the highest material removal rate and minimum tool wear during micro drilling of austenitic stainless steel sheets.
Optimization of tungsten inert gas welding on 6063 aluminum alloy on taguchi ...RSIS International
In this paper, the Taguchi method is used for the
Optimization of Tungsten Inert Gas Welding on 6063
Aluminum Alloy. The Taguchi method L27 is used to
optimize the pulsed TIG welding process parameters of 6063
aluminum alloy weldments for maximizing the mechanical
properties. Analysis of Variance is used to find the impact of
individual factors. Then the optimal parameters of the TIG
welding process is determined and the experimental results
illustrate the proposed approach.
AISI 304 stainless steel have a wide range of applications in the industrial field. The need for
machining AISI 304 SS has not been eliminated fully. The electrode wear rate (EWR) is an
important aspect during electrical discharge machining (EDM). In this investigation an attempt has
been made to assess the factors influencing electrode wear rate on the machining of AISI 304 SS.
Design of experiments (full factorial design) concept has been used for experimentation. The
machining experiments were conducted on a die sinking EDM machine using two levels of factors.
The factors considered were electrode shape, pulse current, pulse on time and pulse off time. A
procedure has been developed to assess and optimize the chosen factors to attain minimum electrode
wear rate by incorporating: (i) response table and response graph; (ii) normal probability plot; (iii)
interaction graphs; (iv) analysis of variance (ANOVA) technique. The results indicated that
electrode shape is a factor, which has greater influence on EWR, followed by pulse off time. Also the
determined optimal conditions really reduce the EWR on the machining of AISI 304 SS within the
ranges of parameters studied.
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machining on two different grade stainless steels under dry and mist conditions.
Stainless steels like AISI 304 and AISI 316L are considered for study. Process
variables like workpiece speed, tool feed and depth of cut are taken for
experimentation on CNC lathe. Responses like surface roughness, power consumption
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IJERA (International journal of Engineering Research and Applications) is International online, ... peer reviewed journal. For more detail or submit your article, please visit www.ijera.com
Finite element modeling of the broaching process of inconel718Phuong Dx
This document summarizes a study that used finite element modeling to simulate the broaching process of Inconel718. The study compared simulation results to experimental data and found good agreement for cutting forces. Models for cutting forces as functions of cutting parameters were developed based on simulation results. Additionally, the effects of rake angle and rising per tooth on chip curling and gullet area ratios were examined. Increasing rake angle or decreasing rising per tooth decreased chip curling diameter. Simulated chip curling diameters and area ratios were larger than recommended design values, suggesting gullet dimensions could be increased to improve chip flow.
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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
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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
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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 Paper Presentation which won the award for 'Best Paper' at 5th International Conference on Industrial Engineering 2019, S.V.N.I.T., Surat, India. Presentation elaborates research carried out for the same paper published in the conference.
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
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processing performance, cutting tool optimization, etc..In this paper, the three-dimensional orthogonal and
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IRJET- Review Paper on of Single Point Cutting Tool with Taguchi Robust ApproachIRJET Journal
This document presents a review paper on simulating a single point cutting tool process using the Taguchi robust design approach. It discusses using finite element modeling (FEM) software to numerically simulate the turning process and analyze three input factors (depth of cut, cutting speed, and rack angle) and two responses (stress and strain). The Taguchi design of experiments technique is used to develop relationships between factors and responses. Regression modeling is then used to develop equations relating the input parameters to output results. Previous research on measuring cutting temperatures, forces, and modeling metal cutting processes is also reviewed to provide context and validate the current study's approach.
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
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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
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Mechanism of Fracture in Friction Stir Processed Aluminium AlloyDr. Amarjeet Singh
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Testing results of a multi-cavity mold for injection molding of MIM 4140 alloy are presented in the article. Recommendations for manufacturing of forming parts of the mold were given. Based on an implemented technological process of casting and subsequent laboratory researches an information was obtained about the condition of a casting (hardness on Super-Rockwell, shrinkage and quality of a surface layer of material before and after heat treatment). Calculated overall dimensions of the forming parts of the project mold will allow making forecast of shrinkage of MIM 4140 alloy after injection molding.
Design of Experiment Machinability Evaluation of Dry Drilling Machinability o...IRJET Journal
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The dynamic stability of machine has its own importance in the quality of the machined product. With the development of new technologies for cutting tools, as the geometries and materials, cutting speeds used today reach values inconceivable for two decades. In the automotive industry steel and cast iron are gradually being replaced by lower density material and even lower costs. In complex shapes tools, heterogeneous material removal in roughing, sudden changes of sections, etc. Stress relieving treatment should be carried out to minimize dimensional variations of form during quenching and tempering. Materials for manufacture of thermal fixing most appropriate for that operating system still needs to be further investigated. Therefore, this study investigated the elastic behavior of the material used in the manufacture of tooling systems for cutting tools. Has been evaluated In fastening system, the temperature variation exerted on the mandrel body region and the thermal expansion where H13 steel can withstand the assembly process by thermal interference. This method can determine the amount of number of cycles until the onset of fatigue that material.
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This document summarizes a study that used finite element modeling to analyze chip formation and thermal effects on tool life during metal cutting operations. The study modeled orthogonal cutting using MARC software to simulate the cutting process and predict tool temperature distributions and vibration. A Johnson-Cook material model was used to represent the workpiece material. Friction during cutting was also modeled. The simulation analyzed how factors like cutting speed and depth affected tool temperature and stability.
This document summarizes a study on the tensile behavior of aluminum plates welded using friction stir welding. Various welding parameters like rotational speed, welding speed, and pin diameter were experimented with to weld an aluminum alloy. Mathematical models were developed using a statistical design of experiments approach to understand the effects of the parameters on tensile strength. It was found that tensile strength decreases with increasing rotational speed, increases with increasing welding speed, and decreases with increasing pin diameter. The maximum tensile strength was achieved at low rotational speed and high welding speed. Regression models for tensile strength were developed and validated to be adequate predictors within 95% confidence level.
1. International Journal of Advanced Engineering Applications, Vol.5, Iss.3, pp.22-27 (2012)
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Finite element simulation in machining of Inconel 718 nickel
based super alloy
E. Muthu1
, K. Senthamarai2
, S.Jayabal3
Department of Mechanical Engineering,
1, 3
A. C. College of Engineering and Technology, Karaikudi.
2
Mookambigai College of Engineering, Kalamavur.
muthuaccetkkdi@yahoo.in1
, ksentha75@yahoo.co.in2
, jayabalsubbaian@rediffmail.com3
Abstract - This paper is focussed on the finite element analysis (FEA) of machining of Inconel 718 superalloy using
DEFORM 2D. Orthogonal cutting experiments are carried out on cylindrical workpiece of Inconel 718 with cutting speed of
50 m/min, feed rate of 0.1 mm/rev. and nose radius of 0.6, 0.8 & 1.0 mm. The Johnson-Cook constitutive equation is
implemented in the finite element code to study the deformation behaviour of Inconel 718 during the machining process. The
simulation results showed that the chip segmentation is not occurred at the low cutting speed and the stress on the machined
surface is residual in nature while stress value is decreased around the uncut surface and the deformed chip. The plastic
strain is higher at the primary zone followed by the secondary shear zone and least at the free end of the chip.
Keywords - Constitutive equation, orthogonal cutting,finite element analysis, Deform 2D.
1 INTRODUCTION
The use of Nickel-based super alloy in aerospace was begun in the 1930’s. Need for the more creep
resistant material than the available austenitic stainless steel propelled research for the development of new
superalloy. The principal characteristics of nickel as an alloy base are highly phase stability of face centered
cubic (FCC) nickel matrix and outstanding strength retention upto 0.7 Tm (melting point).these characteristics
encourage use of nickel base superalloys in vast number of applications subjected to high temperatures1
.
Commercially available nickel base superalloys include Inconel, Nimonic, Rene, Udimet and Pyromet. Inconel
718 is the most frequently used nickel based superalloys; hence this study is focused on an investigation into the
mechanics of machining Inconel 718. Some of the applications of nickel based superalloys are in aircraft gas
turbines (eg. disks, combustion chamber, casings, shafts, exhaust system, blades, vanes, burner, cans, stack gas
reheaters), reciprocating engines (eg. turbochargers, exhaust valves hot plugs, valve seat inserts), metal
processing (eg. hot work tools and dies), space vehicles (eg. aerodynamically heated skins, rocket engine parts)
heat treating equipments (eg. trays, fixtures, conveyor belts, baskets, fans, furnace mufflers), nuclear power
plants, chemical and petrochemical industries and heat exchangers.
High temperature gradients are localized in narrow bands along shear plane due to poor thermal properties
of Inconel 718, leading to weakening the material in the deformation zone. When the rate of thermal softening is
greater than that of strain hardening, material deforms locally, termed as adiabatic shear failure. The type of
chips formed under these conditions is termed as shear localized chips. Oscillations in cutting forces and high
temperatures on the rake face in the contact area can cause rapid tool wear. High pressures developed during
segmented chip formation retards further machining and increase power requirements of the process. Ezugwu et
al.(1999) summarized the properties of nickel based superalloys, contributing to poor machinability. Finite
element analysis has revolutionized the quality of metal cutting research since it was first proposed by Tay et
al.(1974).
Usui et al.(1982) developed the first two dimensional FE model to simulate orthogonal machining which
was based on an elasto-plastic material model using the iterative convergence method for steady state cutting.
Klamecki (1973) explained the initial stages of chip formation in metal cutting by three dimensional models.
Iwata et al. (1984) used a rigid plastic material model with plane strain conditions to the orthogonal cutting
process. Strenkowski et al.(1985) used an updated Lagrangian model to simulate machining without a pre-
formed chip. The phenomenal growth in computing technology has accelerated the use of finite element
methods which has helped to improve the quality of tooling and productivity for the manufacturing industries.
The last two decades has seen a phenomenal rise in the number of FE models and codes used by various
researchers. Deform-2D has been the most popular of the FE codes amongst the researchers due to its superior
simulating capabilities.
Recently, some researchers presented their finite element simulations in machining with new and
inadequacy of the J-C law in modeling due to the absence of thermal softening phenomena, lack of thermo-
dynamical term in the equation and lack of shear localization term, respectively. Lalwani et al.(2009) extended
the Oxley predictive machining theory of the J-C flow stress model by studying the effect of strain in addition to
strain rate and temperature in machining. Sima et al.(2010) developed a modified material model for modelling
2. International Journal of Advanced Engineering Applications, Vol.5, Iss.3, pp.22-27 (2012)
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the serrated chip formation in titanium alloys. Umberllo et al. (2008) employed three different J-C models to
simulate high speed machining of titanium alloys and presented good results.
The J-C model is still the most popular model for simulating machining due to its robustness and its ease of
application in the FE codes, in the present work, the J-C constitutive equation have been used to represent the
flow stress behaviour of Inconel 718 alloy.
2 MATERIAL CONSTITUTIVE MODEL
The flow stress behaviour of Inconel 718 was modeled using Eq.(1), which was proposed by Johnson-
Cook (1983) and describes the flow stress of the material as a function of strain, strain rate and temperature
effects .The three terms represent the individual effects of strain hardening, strain rate hardening and thermal
softening on the flow stress of the material undergoing deformation. The limitations of the JC model are
inability to predict the flow stress at deformations below room temperature, lack of insight into interactions
between strain, strain rate and temperature and lack of thermal softening phenomena. The JC model has been
popularly employed to characterize the material deformation behaviour of various materials due its suitability
for use in FE codes.
σ = [A+Bε n
] [1+ C ln (ε'/ ε'o)] [1 – {(T – T room) / (T melt – T room)} m
] (1)
where σ is the flow stress, ε is the equivalent plastic strain, ε' is the strain rate, ε'o is the reference plastic
strain rate, T is the temperature of the work material, Tmelt is the melting temperature of the work material and
Troom is the room temperature. Coefficient A is the yield strength, B is the hardening modulus, C is the strain rate
sensitivity coefficient, n is the hardening coefficient and m is the thermal softening coefficient. The strain rate ε'
is normalized with a reference strain rate ε'o. The material parameters of the Johnson-Cook model (1983) are
listed in Table 1.
Table 1 Johnson-Cook material model parameters
A[MPa] B[MPa] C n m
1029.100 1477.500 0.060 0.330 1.440
3 FINITE ELEMENT MODELING AND SIMULATION OF ORTHOGONAL CUTTING
3.1 FE model
The finite element modeling was performed in Deform 2D which is based on an updated Lagrangian
formulation that considers the mesh to be attached to the work piece during deformation. The chip shape
develops as a function of deformation process, process parameters and material properties and hence need not to
be predetermined. The work material was highly constrained while tool material was allowed movement in the
X- axis. The thermo-physical properties of the work and tool materials and the flow stress data of Inconel 718
alloy calculated from the material models incorporated into the FE model. The work piece was modeled as
plastic and the tool as rigid materials.
A 10 × 2.5 rectangular cross section was considered for the work piece geometry and meshed with 5000
four noded isoparametric quadrilateral elements with an elemental width of 0.04775 mm and the aspect ratio of
1 to ensure a high density mesh. The tool geometry incorporating the rake and clearance angles of the tool used
in the experiments was meshed with 750 elements. The simulation was carried out with plane strain assumption
and the cutting conditions were identical to the experiments. An automated remeshing algorithm integrated in
the FE code ensures the continuity of the chip formation. The simulated results were viewed through the post
processor and the results are noted at near steady state conditions. Experimental conditions for machining
Inconel 718 are in the Table 2.
Table 2 Experimental conditions for machining Inconel 718
Workpiece Inconel 718
Tool material PCBN
Inserts Model Number CNMG 120408 MP, KC 5010
Tool rake angle -5⁰
Tool clearance angle +5⁰
Tool nose radius(mm) 0.6, 0.8 & 1.0
Feed rate (mm/rev.) 0.1
Cutting speed (m/min) 50
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Depth of cut (mm) 0.5
Cutting condition Dry
3.2 Fracture criterion
The Cockroft and Latham (1968) criterion given in Eq. (2) was employed in the FE code to account for
the fracture phenomena which cause segmented chips typical of titanium alloys even at low cutting speeds. It
states that fracture occurs when the integral of the largest tensile principal stress component over the plastic
strain path reaches the critical damage value, D.
(2)
where εf is the effective strain, σ1 is the maximum principal stress and D is a material constant. The critical
damage value is computed for every element at each time step and initiates a crack when this value is reached in
two steps:
(i) the element is deleted with all parameters related to it and
(ii) the rough boundary produced by element deletion is smoothed by cutting out the considered rough
angle and adding new points.
3.3 Friction modeling
The constant coulomb friction model given in Eq. (3) was employed in the FE code to model the friction
characteristics of Inconel 718 alloy machining. The simple friction law was chosen since it has been proved that
coefficient of friction is more relevant to frictional modeling than the law on which it is based and the forces
data are sufficiently reliable and less sensitive over a wide range of frictional values from 0.2 to 0.8. Filice et
al.(2007).
τ = μσn
(3)
where τ is the shear stress, μ is the coefficient of friction and σn is the normal stress. The shear stress is
expressed as a product of Coulomb friction coefficient with the normal stress. The FE simulation is performed
with available μ and D values [Deform User manual] and the cutting force and chip morphology compared with
experiments. The μ and D values are modified till there is no appreciable change in the cutting forces and chip
morphology outputs measured. In this work a μ value of 0.6 and D value of 100 was employed for the
comparative study.
4 RESULTS & DISCUSSION
The finite element results for effective stress, strain, temperature distribution and damage with the input
material model for different tool nose radius are presented in this chapter. The analysis is presented for cutting
speed of 50 m/min and feed rate of 0.1 mm/rev for all different tool nose radius values (0.6, 0.8 & 1.0 mm).the
cutting speed and feed rate at constant in this study. The FE output was observed at nearly steady state
conditions in this study.
4.1 Stress Analysis
The von mises stress plot for effective stress distribution for 0.6, 0.8 & 1.0 mm tool nose radius are shown
in Fig. 1. The negative rake angle causes the greater stress on the work material and the tool at the point of
contact. The stress on the machined surface is residual in nature while stress value is decreased around the uncut
surface and the deformed chip.
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Fig. 1 Effective stress distribution plot for different nose radius values
4.2 Strain Distribution
Fig. 2 shows the predicted effective strain distribution for 0.6, 0.8 & 1.0 mm tool nose radius values. The
plastic strain is higher at the primary zone followed by the secondary shear zone and least at the free end of the
chip. The simulated models for the three nose radius presented similar patterns. There appears to be minor
variations in the primary and secondary deformation zones. The higher stress near the shear plane for radius
1.0mm and 0.8mm should suggest higher deformations, but only 0.8mm replicates this proposition. 1.0mm and
0.8mm shows higher deformation at the shear plane tool chip contact respectively.
Fig. 2 Effective strain distribution for different nose radius values
4.3 Temperature Distribution
Fig. 3 shows that the temperature distribution for the various nose radius heat transfers in the machining
process takes place primarily in the shear zone was the plastic work is converted into heat and the chip tool
interface where the frictional heat is generated. Some heat is lost to the ambience through convection and some
transfer to the outgoing chip and the cutting tool through conduction. The low thermal conductivity of nickel
alloy ensures poor heat dissipation, resulting in rapid tool wear and reduction in the tool life. Hence cutting fluid
and the cryogenic coolants are necessary to quickly remove the latent heat.
In the FE model the work material is treated as plastic and the tool as rigid to facilitate better
understanding of the heat transfer due plastic deformation of the nickel alloy during machining. Hence, the
thermal analysis is concentrated on work material alone. The temperature reaches steady state quickly after the
initial increase in the primary and the secondary deformation zone. The experimental temperature is usually the
highest at the chip tool interface (secondary deformation zone) followed by the shear plane zone and least in the
uncut surface. The simulated maximum temperatures are more within the chips due to the low thermal
conductivity which does not allow quick heat dissipation form the deformed chip. The temperature distribution
in the primary and tertiary zones is as expected in the machining process.
The effect of cutting speed and friction modelling also has an effect on the temperature distribution.
Generally the FE prediction for temperature are likely to show lesser than normal values (as observed in
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literature), because of the short cutting process simulation which prevents the temperature form reaching steady
state.
Fig.3 Temperature distribution plot for different nose radius values
4.5 Damage Distribution
Fig. 4 shows that damage value distribution in the chip during cutting of Inconel 718. The location of a
larger damage value is correctly corresponding to the above discussed stress state in chip segmentation. It can be
seen that high damage value is located at a different region as the nose radius changes.
Fig.4 Damage distribution plot for different nose radius values
5 CONCLUSION
The present study was focused on the finite element simulation of turning process of Inconel 718 material
for various nose radius values. The Johnson-Cook material constitutive model was used to represent material
behaviour in the present investigation. The following observations were made from the study.
(i) Chip segmentation is not occurred in low cutting speed. In this case upto 50 m/min no chip segmentation
was observed.
(ii) Negative rake inserts produces compressive stress while positive rake inserts give tensile stress.
(iii) The nose radius increases the contact length between the tool and chip interface is increase and the
compressive stress decreases. The residual stress in the machined surface is residual in nature while the
stress value decreases in the deformed chip and uncut surface.
(iv) The plastic strain is higher at the primary zone followed by the secondary shear zone and least at the free
end of the chip. This chip shows regions of high and low strain across the chip thickness.
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