Finite element modelling of heat transfer analysis in machining of isotropic materials
01 May 1999-International Journal of Heat and Mass Transfer (Pergamon)-Vol. 42, Iss: 9, pp 1569-1583
TL;DR: In this article, a steady state 2D and 3D finite element analysis has been carried out for heat transfer analysis in machining of isotropic materials, and the effect of the convective heat transfer coefficient on machining performance has been highlighted.
About: This article is published in International Journal of Heat and Mass Transfer.The article was published on 1999-05-01. It has received 23 citations till now. The article focuses on the topics: Machining & Heat transfer coefficient.
Citations
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Dissertation•
01 Jan 2011
TL;DR: In this paper, an ultrasonic vibratory tool (UVT) is designed and analyzed using ANSYS ® environment for calculation of its natural frequency and working amplitude of vibration An ultrasonic assisted turning system is designed considering cutting tool as a cantilever beam Experimental study has been carried out to find the difference between ultrasonic-assisted and conventional turning at different cutting conditions taking carbon steel (a general purpose engineering material) as the work piece material.
Abstract: In recent years applications of hard materials in different industries, like aerospace, defence and petrochemicals sectors etc have been increased remarkably The machining of these hard materials is very difficult in conventional turning process Ultrasonic assisted turning is a suitable and advanced process for machining hard and brittle material because of its intermittent cutting mechanism In the present work, an ultrasonic vibratory tool (UVT) is designed and analyzed using ANSYS ® environment for calculation of its natural frequency and working amplitude of vibration An ultrasonic assisted turning system is designed considering cutting tool as a cantilever beam Experimental study has been carried out to find the difference between ultrasonic- assisted and conventional turning at different cutting conditions taking carbon steel (a general purpose engineering material) as the work piece material It is found that ultrasonic assisted turning reduces the surface roughness and cutting force in comparison with conventional turning It is well known that cutting force and surface finish/roughness are two major parameters which affect the productivity of the turning process In the present work, Grey based Taguchi method is used to optimize both cutting force and surface roughness to find the best possible machining parameters under the used experimental working conditions Also, second order response models for the surface roughness and cutting force are developed and confirmation experiments are conducted
3 citations
Cites background from "Finite element modelling of heat tr..."
...[34] developed a three dimensional finite element model using isotropic materials and study the effect of the convective heat transfer....
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10 Apr 2012
TL;DR: In this article, the authors show that multilayer coated tools can have a positive impact in improving machining performance, especially at high thermal loads during the cutting process, which has a major influence on tool performance.
Abstract: High thermal loads during the cutting process can have a major influence on tool performance. Multilayer coated tools can have a positive impact in improving machining performance, especially at hi...
3 citations
Cites methods from "Finite element modelling of heat tr..."
...Ramesh et al.21 carried out a study using FE modelling with steady state 2D and 3D models for heat transfer analysis in machining of isotropic materials....
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...Ramesh et al.(21) carried out a study using FE modelling with steady state 2D and 3D models for heat transfer analysis in machining of isotropic materials....
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Dissertation•
29 May 2015
TL;DR: In this paper, an attempt has been made to study the temperature and stress behaviour of tool insert, which in this case is taken as SNMG 120408 with respect to turning operation performed on Inconel 825 superalloy.
Abstract: Machining of nickel based super-alloys has gained a lot of importance in the last decade or so owing to their applications in areas like power generation (gas turbine), military aircrafts, marine propulsion and nuclear reactors. However, during high speed machining it faces a lot of problems in regard to thermal stress, and strain hardening, leading to premature tool failure. Use of cooling lubricants has declined in popularity because they pose a lot of problem with regards to their disposal, reuse and environmental safety. As a result coated tools have come into picture which improve the tool life in case of dry machining and increase productivity owing to their high thermal stability and integrity. Inconel 825 is a relatively newer grade of nickel bases super-alloys, on which a few tests have only been done. An attempt has been made to study the temperature and stress behaviour of tool insert, which in this case is taken as SNMG 120408 with respect to turning operation performed on Inconel 825 superalloy. The tool tip temperatures were found out and the temperature profiles were plotted for various feed and cutting speeds. Initial principal stress induced on the tool is also calculated. The variation of tool tip temperature and effective stress with respect to different cutting conditions were analysed and justified with respect to known knowledge. Comparative study has also been made between the uncoated tool and a CVD coated tool for the same cutting conditions.
References
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01 Jun 1963
TL;DR: In this paper, the authors used a photographic technique for the determination of the complete temperature distribution in the orthogonal metal cutting process; they are found to disagree with previous theoretical predictions.
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.
251 citations
TL;DR: In this paper, the authors proposed an energy-based method to predict chip formation and cutting force for a single point tool of arbitrary geometry, 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.
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.
232 citations
22 Dec 2014
TL;DR: In this paper, the authors present a survey of the state-of-the-art technologies for the Mechanical Engineers, including virtual reality, simulation, and statistical quality control, as well as a detailed cost estimator.
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.
224 citations
01 Jun 1974
TL;DR: In this paper, the temperature distribution for typical cases of orthogonal machining with a continuous chip was obtained numerically by solving the steady two-dimensional energy equation using the finite element method.
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.
198 citations
TL;DR: In this article, the finite element method is applied to calculate the temperatures in orthogonal machining with account being taken of the finite plastic zones, in which the chip is formed and in which further plastic flow occurs at the tool-chip interface, and also of the shape and thermal properties of the cutting tool.
148 citations