Finite element modelling of heat transfer analysis in machining of isotropic materials

Finite element analysis and simulation of machining: an addendum: A bibliography (1996–2002)

Abstract: This paper gives a bibliographical review of the finite element methods applied to the analysis and simulation of welding processes The bibliography is an addendum to the finite element analysis and simulation of welding: a bibliography (1976–96) published in Modelling Simul Mater Sci Eng (1996) 4 501–33 The added bibliography at the end of this paper contains approximately 550 references to papers and conference proceedings on the subject that were published in 1996–2001 These are classified in the following categories: modelling of welding processes in general; modelling of specific welding processes; influence of geometrical parameters; heat transfer and fluid flow in welds; residual stresses and deformations in welds; fracture mechanics and welding; fatigue of welded structures; destructive and non-destructive evaluation of weldments and cracks; welded tubular joints, pipes and pressure vessels/components; welds in plates and other structures/components

Modelling of hard part machining

Abstract: The paper initially reviews the use of finite element modelling (FEM) to determine orthogonal machining performance. Over the last decade, the development and use of FEM to evaluate the effect of tool coatings, cutting environment and chip formation on cutting forces and temperatures, etc., has increased dramatically. The different chip separation criteria and FEM software used by various researchers are detailed. An FE model is presented using ABAQUS/Explicit™ to simulate continuous and segmental chip formation when machining AISI H13 tool/die steel heat treated to ∼49 HRC with polycrystalline cubic boron nitride (PCBN) tools. The work utilised the shear failure criteria and element deletion/adaptive remeshing modules found in ABAQUS/Explicit. The assignment of tool/chip interface friction was dependent on the magnitude of the direct stress acting on the rake face of the tool. Experimental data involving chip morphology and cutting forces were used to validate the model. The temperature generated in the shear zone was higher with the segmented chip (up to 700 °C) than with the continuous chip (up to 250 °C), for the same machining parameters.

Effect of lubrication and cutting parameters on ultrasonically assisted turning of Inconel 718

Abstract: The paper further develops the finite element (FE) model of ultrasonically assisted turning (UAT) discussed in Mitrofanov et al. [A.V. Mitrofanov, V.I. Babitsky, V.V. Silberschmidt, Finite element analysis of ultrasonically assisted turning of Inconel 718, J. Mater. Process. Technol., in press]. The advanced FE model (based on the general FE code MSC.MARC) allows transient, coupled thermomechanical simulations of both UAT and conventional turning of elasto-plastic materials. This model is used to study the effect of cutting parameters (such as the cutting speed, depth of cut and feed rate) and influence of lubrication on various features of two turning techniques, including cutting forces and chip shapes. The recently obtained results on three-dimensional FE modelling of UAT are also presented. This 3D model allows a study of chip formation in oblique turning.

3D finite element analysis of ultrasonically assisted turning

Abstract: Ultrasonically assisted turning (UAT) is an advanced machining technique, where high-frequency vibration is superimposed on the movement of a cutting tool. Compared to conventional turning (CT), this technique allows significant improvements in processing intractable materials. The paper presents a recently developed 3D model of UAT as an extension to our initial 2D model [A.V. Mitrofanov, V.I. Babitsky, V.V. Silberschmidt, J. Mater. Process. Technol. 153–154 (2004) 233]. This model allows studying various 3D effects in turning, such as oblique chip formation, as well as to analyse the influence of tool geometry on process parameters, e.g. cutting forces and stresses generated in the workpiece material. The FE model is used for transient, coupled thermomechanical simulations of elasto-plastic materials under conditions of both UAT and CT. It is used to study the effect of cutting parameters (such as the cutting speed, depth of cut and feed rate) and friction on UAT and CT. Numerical results are validated by experimental tests.

A numerical model to determine temperature distribution in orthogonal metal cutting

Abstract: In this study, a thermal analysis model is developed to determine temperature distribution in orthogonal metal cutting using finite elements method. The model calculates the temperature distribution as a function of heat generation. The heat generation was introduced in the primary deformation zone, the secondary deformation zone and along the sliding frictional zone at the tool–chip interface, as well. The location and shapes of these zones was determined based on the literature work done so far and the model results. The temperature dependency of material properties was included in the model. A series of thermal simulations have been performed, and the value and location of maximum temperature have been determined for various cutting conditions. The comparison of the simulations with earlier works gave promising trend for the presented model. The thermal aspects of metal cutting as a result of the model findings were discussed.

Temperatures in Orthogonal Metal Cutting

Abstract: The results of a photographic technique for the determination of the complete temperature distribution in the orthogonal metal cutting process are presented; they are found to disagree with previous theoretical predictions. The temperatures along the tool rake face are of particular interest because they are thought to affect the wear of the cutting tool and friction between the chip and tool; it is found that these temperatures have been considerably over-estimated by previous work. By introducing the width of the secondary deformation zone, i.e. the extent of sub-surface deformation due to friction at the tool-chip interface, as a new variable, it is found that more consistent predictions of rake face temperatures can be made. From this work information has been obtained on the shape of the zones of plastic deformation in metal cutting and on the distribution of heat generation within these zones.

Mechanical engineers' handbook

Abstract: Partial table of contents: MATERIALS AND MECHANICAL DESIGN. Structured of Solids (C. Drummond). Steel (R. King). Nickel and Its Alloys (T. Bassford & J. Hosier). Titanium and Its Alloys (D. Knittel & J. Wu). Stress Analysis (F. Fisher). Virtual Reality--A New Technology for the Mechanical Engineer (T. Dani & R. Gadh). Ergonomic Factors in Design (B. Rutter & A. Becka). Failure Considerations (J. Collins & S. Daniewicz). SYSTEMS AND CONTROLS. Mathematical Models of Dynamic Physical Systems (K. White). Measuremenst (E. Hixson & E. Ripperger). MANUFACTURING ENGINEERING. Classification Systems (D. Allen). Statistical Quality Control (M. Zohdi). ENERGY, POWER, AND POLLUTION CONTROL TECHNOLOGY. Fluid Mechanics (R. Olson). Furnaces (C. Cone). Gaseous Fuels (R. Reed). Air Heating (R. Reed). Gas Turbines (H. Miller). Air Compressors (J. Foszcz). Water Pollution--Control Technology (C. Brunner). MANAGEMENT, FINANCE, QUALITY, LAW, AND RESEARCH. Managing People (H. Thamhain). Detailed Cost Estimating (R. Stewart). Patents (D. Burge & B. Burge). Sources of Mechanical Engineering Information (F. Dusold & M. Kutz). Index.

Analytical Prediction of Three Dimensional Cutting Process—Part 3: Cutting Temperature and Crater Wear of Carbide Tool

Abstract: Through the energy method proposed in the previous parts of this study, it is possible to predict chip formation and cutting force for a single point tool of arbitrary geometry. By using the predicted results together with an assumption made on the stress distribution on the tool face, the temperature distribution within chip and tool is obtained through a numerical analysis. A characteristic equation of crater wear of carbide tool is derived theoretically and verified experimentally. Computer simulation of crater wear development is then carried out by using the characteristic equation, and the predicted distributions of the stress and the temperature.

Using the Finite Element Method to Determine Temperature Distributions in Orthogonal Machining

Abstract: Temperature distributions for typical cases of orthogonal machining with a continuous chip were obtained numerically by solving the steady two-dimensional energy equation using the finite element method. The distribution of heat sources in both the primary and secondary zones was calculated from the strain-rate and flow stress distributions. Strain, strain-rate and velocity distributions were calculated from deformed grid patterns obtained from quick-stop experiments. Flow stress was considered as a function of strain, strain-rate and temperature. The chip, workpiece and tool (actual shape and size) were treated as one system and material properties such as density, specific heat and thermal conductivity were considered as functions of temperature.

A numerical method for calculating temperature distributions in machining, from force and shear angle measurements

Abstract: The finite element method is applied to calculate the temperatures in orthogonal machining with account being taken of the finite plastic zones, (a) in which the chip is formed and (b) in which further plastic flow occurs at the tool-chip interface, and also of the shape and thermal properties of the cutting tool. Mathematical models of both primary and secondary deformation are described. These allow complete temperature distributions to be obtained, given only the experimental values of tool force and chip thickness, and the thermal properties of the work and tool. The method has potential use in a predictive theory where only the fundamental properties of the work and tool materials are known.