Beruflich Dokumente
Kultur Dokumente
5 International & 26 All India Manufacturing Technology, Design and Research Conference (AIMTDR 2014) December 12 –14 , 2014,
IIT Guwahati, Assam, India
Abstract
Micromachining of industrial products, is playing an important role in manufacturing of axi-symmetricminiaturized
parts especially in biomedical and aerospace applications.This paper presents the development of 3D oblique finite
element modeling for prediction of cutting forces, thrust force, feed force, and tool chip interface temperatureduring
micro turning process. Titanium alloy (Ti6Al4V) and Coated carbide tool (TiN/AlTiN) is considered as work and
tool material respectively.Johnson- Cook material model with strain gradient plasticity is used to represent the flow
stress of the work material. When uncut chip thickness is equal to or less than the edge radius, thrust force is
dominant over the cutting force due to rubbing and ploughing action. When cutting speed increases there is decrease
in cutting force due to thermal softening effect. When depth of cut and uncutchip thickness is less than edge radius
there is increase in specific cutting energy due to material strengthening effects. Tool chip interface temperature
increases by increasing the cutting speed.Simulated cutting force values are agree well with the experiment values.
Key words: FEM, Cutting forces, edge radius.
414-1
influence of micro edge n as rigid and workpiece is
geometry (chamfer i considered as
insert, uniform hone t viscoplastic material. To
insert, variable hone e get the influence of edge
insert, waterfall hone radius a fine mesh
insert) on forces, stress, e density is given at the tip
friction and tool wear in l of the tool is shown in
PcBN tool. Results
95figure
e
suggested that variable m 2. The edge radius of
micro geometry insert e the cutting insert is 15
has reduced tool wear, n µ m is shown in figure 6.
heat generation and less t
plastic strain.
m Figure 1
Most of the
o Oblique
work done in the
d cutting
literature study
e
is
l
2D and 3D orthogonal Figure 1 shows the
FEM for macro There are three oblique cutting where
machining. To get the formulations used in the cutting edge is inclined at
actual cutting process, finite element model of 95° to the feed velocity.
3D oblique finite element machining process: Tool is considered Fine mesh
model has been Lagrangian, Eulerian, or 0.2mm nose
developed in the present Arbitrary
investigation. Thereare radius
LagrangianEulerian.
very few investigations Figure 2 Geometry of
Material being removed insert with finite
made so far on from the workpiece is element mesh
simulation of micro exposed to severe plastic
turning of Titanium deformation and it causes
alloy. This paper is distortion of elements Minimum element size of
essential to understand during FEM simulation. the workpiece is
the mechanism of Therefore mesh 0.002mm given in all
material removal at the regeneration in the simulation conditions.
micro scale. workpiece is needed. In The shape of the
addition this chip element is four node
2 separation criteria must tetrahedron element.
. be provided in Eulerian Figure 3 shows the
approach. To overcome simplified model of
this problem, in this workpiece fixed at
M bottom portion in
paper finite element
e X,Y,and Z directions.In
simulation has been
t carried out by implicit the present study uncut
h Lagrangian method in chip thickness is assumed
o which the chip is formed to be 10, 15, 20 microns.
by continuous remeshing Figure 4 shows coating
d of AlTiN and TiN over
using DEFORM 3D
o carbide tool.
software. Ozelet al.
l (2011) studied the FEM
o of machining of inconel
g 718 by using two
y different FE software.
Results suggested that
2 predicted cutting forces,
. cutting temperature,
1 strain, and stress values
are almost similar in both
F DEFORM 3D and Figure3
i ABAQUS/Explicit. Workpiece
fixed at
bottom
portion
F
ig
u
r
e
4
C
o
a
te
d
c
a
r
b
i
d
e
i
n
s
e
rt
2.2 Material modeling Shear friction law and colulomb friction law are used to
∈& −
m represent the friction between tool and chip interface.
T To
σ = ( A + B ∈n ) 1 + 1 − τ
C ln
∈& 0 Tm − To m= (2)
µ
1/ 2
k
where,m = shear friction factor.
(1) τ = frictional shear stress.
18a 2 b G 2
1
+
m 2 k = work material flow stress.
∈ & −
T T
L ( A + B ∈ ) 1 + C ln
n
1 −
o
A constant shear friction factor m = 0.95 is used in all
∈& 0 Tm − To
simulation conditions Ozelet al. (2010).Table 1 shows
the thermo mechanical properties of tool and workpiece
material. The formula for calculating shear frictor is
shown in Equation 2, and specific cutting energy is
where (A) yield strength of the material, (B) strain shown in Equation 3.
hardening modulus, (C) strain rate sensitivity
coefficient, ( ) plastic strain, ( ) strain rate, ( ) Cutting tool
reference plastic strain rate, (T) Workpiece temperature,
(Tm)Melting temperature, (To) Room temperature, (m) Edge
thermal softening coefficient, (n) Hardening coefficient, radius
(G) shear modulus, (L) characteristic length in strain
gradient plasticity model, (b) magnitude of burger Saw tooth
vector, (a) constant. The optimized material constant for chip
John and cook model are; A = 782.7MPa, B = 498.MPa, formation
C = 0.028, m= 1, n = 0.28, To= 20°C, Tm= 1660°C.
Modified Johnson–Cook material model with strain
Workpiece
gradient plasticity is used to represent the flow stress of
the work material as shown in Equation 1 Shen and
Ding (2013). Figure 6 Finite element model
Fc × V c
Specific cutting energy =
DOC ×Vc × f
(3)
Fc = Cutting force, N
Vc = Cutting speed, m/min
DOC= Depth of cut, µ
mf = feed, µ m/rev
R
e
s
u
l
t
s
a Figure 9
n Variation of
d forces with time
at
19m/min,
d
20µm/rev,
i
10µm
s
depth of
c Figure 8 Variation cut.
u of forces with
s time at
s 19m/min, 15µm/rev, thrust force coming
i 10µm depth of cut. close, and indicates
o that it is not favorable
n condition for
uncutchip thickness machining. There is
3.1
thurst force is more than no much variation in
Effe
the cutting force due to axial force when
ct of
rubbing and ploughing cutting speed
force
action is shown in the increases from
s on
figure 7 and 8. When 19m/min to 75m/min.
edge
uncut chip thickness is Figure 10 shows the
radi
greater variation of forces
us
with time at 57m/min,
It is observed 20 µ m/rev, and 30µ m
from the simulation depth of cut.
3.3 Effect of cutting forces on feed rate and depth and hence there is increase of tool chip temperature
of cut. by increasing the cutting speed.
Figure 11 shows the variation of cutting force with 3.5 Finite element model validation
feed rate at 19m/min. Cutting force increases with
increase of feed rate and depth of cut due to Micro turning of Ti6Al4V have been carried
increased volume of material removal. out using coated carbide tool (AlTiN/TiN) in micro
turning setup at IIT Madras. Experiments were
conducted by varying cutting speed, feed and depth
of cut. Simulated force values are compared with
experimental values.
3.4 Specific cutting energy Figure 13 Variation of tool chip temperature with
cutting speed at 20 µm/rev,30µm depth of cut.