Investigations on the Effects of Different Tool Edge Geometries in the Finite Element Simulation of Machining

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WAN, Lei ;WANG, Dazhong ;GAO, Yayun .
Investigations on the Effects of Different Tool Edge Geometries in the Finite Element Simulation of Machining. 
Strojniški vestnik - Journal of Mechanical Engineering, [S.l.], v. 61, n.3, p. 157-166, june 2018. 
ISSN 0039-2480.
Available at: <https://www.sv-jme.eu/article/investigations-on-the-effects-of-different-tool-edge-geometries-in-the-finite-element-simulation-of-machining/>. Date accessed: 07 mar. 2021. 
doi:http://dx.doi.org/10.5545/sv-jme.2014.2051.
Wan, L., Wang, D., & Gao, Y.
(2015).
Investigations on the Effects of Different Tool Edge Geometries in the Finite Element Simulation of Machining.
Strojniški vestnik - Journal of Mechanical Engineering, 61(3), 157-166.
doi:http://dx.doi.org/10.5545/sv-jme.2014.2051
@article{sv-jmesv-jme.2014.2051,
	author = {Lei  Wan and Dazhong  Wang and Yayun  Gao},
	title = {Investigations on the Effects of Different Tool Edge Geometries in the Finite Element Simulation of Machining},
	journal = {Strojniški vestnik - Journal of Mechanical Engineering},
	volume = {61},
	number = {3},
	year = {2015},
	keywords = {orthogonal cutting; tool geometry; finite element method (FEM); dead metal zone},
	abstract = {This work focuses on the effects of cutting edge geometries on dead metal zone formation, as well as stress and temperature distributions in orthogonal cutting of P20 material using finite element method (FEM) simulation with sharp, chamfered, double chamfered and blunt tools. The cutting process is simulated with Arbitrary Lagrangian-Eulerian (ALE) approach in ABAQUS/Explicit. The simulation results suggest that the tool edge geometry influences the shape of dead metal zone considerably, while having little influence on the chip formation. An analysis of thermo-mechanical coupling was also conducted, and the results show that the stress distribution is affected by the temperature distribution and cutting speed because of the thermal softening effect and the strain rate hardening. A common analytical model is introduced to predict the residual stress, and equivalent Mises residual stresses are all calculated with four different tools to suggest that the tool edge geometry has a significant effect on the residual stress. The experiments are conducted using a CNC with former four kinds of tools at a speed of 480 m/min, and the residual stresses beneath the machined surface were measured with X-ray diffraction and electro-polishing techniques, and a chamfer tool at three different cutting speeds (250, 600 and 1000 m/min) to obtain the forces. The machining forces in both the cutting and thrust directions increases as the chamfer angle increases and decreases as the cutting speed increases.},
	issn = {0039-2480},	pages = {157-166},	doi = {10.5545/sv-jme.2014.2051},
	url = {https://www.sv-jme.eu/article/investigations-on-the-effects-of-different-tool-edge-geometries-in-the-finite-element-simulation-of-machining/}
}
Wan, L.,Wang, D.,Gao, Y.
2015 June 61. Investigations on the Effects of Different Tool Edge Geometries in the Finite Element Simulation of Machining. Strojniški vestnik - Journal of Mechanical Engineering. [Online] 61:3
%A Wan, Lei 
%A Wang, Dazhong 
%A Gao, Yayun 
%D 2015
%T Investigations on the Effects of Different Tool Edge Geometries in the Finite Element Simulation of Machining
%B 2015
%9 orthogonal cutting; tool geometry; finite element method (FEM); dead metal zone
%! Investigations on the Effects of Different Tool Edge Geometries in the Finite Element Simulation of Machining
%K orthogonal cutting; tool geometry; finite element method (FEM); dead metal zone
%X This work focuses on the effects of cutting edge geometries on dead metal zone formation, as well as stress and temperature distributions in orthogonal cutting of P20 material using finite element method (FEM) simulation with sharp, chamfered, double chamfered and blunt tools. The cutting process is simulated with Arbitrary Lagrangian-Eulerian (ALE) approach in ABAQUS/Explicit. The simulation results suggest that the tool edge geometry influences the shape of dead metal zone considerably, while having little influence on the chip formation. An analysis of thermo-mechanical coupling was also conducted, and the results show that the stress distribution is affected by the temperature distribution and cutting speed because of the thermal softening effect and the strain rate hardening. A common analytical model is introduced to predict the residual stress, and equivalent Mises residual stresses are all calculated with four different tools to suggest that the tool edge geometry has a significant effect on the residual stress. The experiments are conducted using a CNC with former four kinds of tools at a speed of 480 m/min, and the residual stresses beneath the machined surface were measured with X-ray diffraction and electro-polishing techniques, and a chamfer tool at three different cutting speeds (250, 600 and 1000 m/min) to obtain the forces. The machining forces in both the cutting and thrust directions increases as the chamfer angle increases and decreases as the cutting speed increases.
%U https://www.sv-jme.eu/article/investigations-on-the-effects-of-different-tool-edge-geometries-in-the-finite-element-simulation-of-machining/
%0 Journal Article
%R 10.5545/sv-jme.2014.2051
%& 157
%P 10
%J Strojniški vestnik - Journal of Mechanical Engineering
%V 61
%N 3
%@ 0039-2480
%8 2018-06-27
%7 2018-06-27
Wan, Lei, Dazhong  Wang, & Yayun  Gao.
"Investigations on the Effects of Different Tool Edge Geometries in the Finite Element Simulation of Machining." Strojniški vestnik - Journal of Mechanical Engineering [Online], 61.3 (2015): 157-166. Web.  07 Mar. 2021
TY  - JOUR
AU  - Wan, Lei 
AU  - Wang, Dazhong 
AU  - Gao, Yayun 
PY  - 2015
TI  - Investigations on the Effects of Different Tool Edge Geometries in the Finite Element Simulation of Machining
JF  - Strojniški vestnik - Journal of Mechanical Engineering
DO  - 10.5545/sv-jme.2014.2051
KW  - orthogonal cutting; tool geometry; finite element method (FEM); dead metal zone
N2  - This work focuses on the effects of cutting edge geometries on dead metal zone formation, as well as stress and temperature distributions in orthogonal cutting of P20 material using finite element method (FEM) simulation with sharp, chamfered, double chamfered and blunt tools. The cutting process is simulated with Arbitrary Lagrangian-Eulerian (ALE) approach in ABAQUS/Explicit. The simulation results suggest that the tool edge geometry influences the shape of dead metal zone considerably, while having little influence on the chip formation. An analysis of thermo-mechanical coupling was also conducted, and the results show that the stress distribution is affected by the temperature distribution and cutting speed because of the thermal softening effect and the strain rate hardening. A common analytical model is introduced to predict the residual stress, and equivalent Mises residual stresses are all calculated with four different tools to suggest that the tool edge geometry has a significant effect on the residual stress. The experiments are conducted using a CNC with former four kinds of tools at a speed of 480 m/min, and the residual stresses beneath the machined surface were measured with X-ray diffraction and electro-polishing techniques, and a chamfer tool at three different cutting speeds (250, 600 and 1000 m/min) to obtain the forces. The machining forces in both the cutting and thrust directions increases as the chamfer angle increases and decreases as the cutting speed increases.
UR  - https://www.sv-jme.eu/article/investigations-on-the-effects-of-different-tool-edge-geometries-in-the-finite-element-simulation-of-machining/
@article{{sv-jme}{sv-jme.2014.2051},
	author = {Wan, L., Wang, D., Gao, Y.},
	title = {Investigations on the Effects of Different Tool Edge Geometries in the Finite Element Simulation of Machining},
	journal = {Strojniški vestnik - Journal of Mechanical Engineering},
	volume = {61},
	number = {3},
	year = {2015},
	doi = {10.5545/sv-jme.2014.2051},
	url = {https://www.sv-jme.eu/article/investigations-on-the-effects-of-different-tool-edge-geometries-in-the-finite-element-simulation-of-machining/}
}
TY  - JOUR
AU  - Wan, Lei 
AU  - Wang, Dazhong 
AU  - Gao, Yayun 
PY  - 2018/06/27
TI  - Investigations on the Effects of Different Tool Edge Geometries in the Finite Element Simulation of Machining
JF  - Strojniški vestnik - Journal of Mechanical Engineering; Vol 61, No 3 (2015): Strojniški vestnik - Journal of Mechanical Engineering
DO  - 10.5545/sv-jme.2014.2051
KW  - orthogonal cutting, tool geometry, finite element method (FEM), dead metal zone
N2  - This work focuses on the effects of cutting edge geometries on dead metal zone formation, as well as stress and temperature distributions in orthogonal cutting of P20 material using finite element method (FEM) simulation with sharp, chamfered, double chamfered and blunt tools. The cutting process is simulated with Arbitrary Lagrangian-Eulerian (ALE) approach in ABAQUS/Explicit. The simulation results suggest that the tool edge geometry influences the shape of dead metal zone considerably, while having little influence on the chip formation. An analysis of thermo-mechanical coupling was also conducted, and the results show that the stress distribution is affected by the temperature distribution and cutting speed because of the thermal softening effect and the strain rate hardening. A common analytical model is introduced to predict the residual stress, and equivalent Mises residual stresses are all calculated with four different tools to suggest that the tool edge geometry has a significant effect on the residual stress. The experiments are conducted using a CNC with former four kinds of tools at a speed of 480 m/min, and the residual stresses beneath the machined surface were measured with X-ray diffraction and electro-polishing techniques, and a chamfer tool at three different cutting speeds (250, 600 and 1000 m/min) to obtain the forces. The machining forces in both the cutting and thrust directions increases as the chamfer angle increases and decreases as the cutting speed increases.
UR  - https://www.sv-jme.eu/article/investigations-on-the-effects-of-different-tool-edge-geometries-in-the-finite-element-simulation-of-machining/
Wan, Lei, Wang, Dazhong, AND Gao, Yayun.
"Investigations on the Effects of Different Tool Edge Geometries in the Finite Element Simulation of Machining" Strojniški vestnik - Journal of Mechanical Engineering [Online], Volume 61 Number 3 (27 June 2018)

Authors

Affiliations

  • Shanghai University of Engineering Science, College of Mechanical Engineering, China 1

Paper's information

Strojniški vestnik - Journal of Mechanical Engineering 61(2015)3, 157-166

https://doi.org/10.5545/sv-jme.2014.2051

This work focuses on the effects of cutting edge geometries on dead metal zone formation, as well as stress and temperature distributions in orthogonal cutting of P20 material using finite element method (FEM) simulation with sharp, chamfered, double chamfered and blunt tools. The cutting process is simulated with Arbitrary Lagrangian-Eulerian (ALE) approach in ABAQUS/Explicit. The simulation results suggest that the tool edge geometry influences the shape of dead metal zone considerably, while having little influence on the chip formation. An analysis of thermo-mechanical coupling was also conducted, and the results show that the stress distribution is affected by the temperature distribution and cutting speed because of the thermal softening effect and the strain rate hardening. A common analytical model is introduced to predict the residual stress, and equivalent Mises residual stresses are all calculated with four different tools to suggest that the tool edge geometry has a significant effect on the residual stress. The experiments are conducted using a CNC with former four kinds of tools at a speed of 480 m/min, and the residual stresses beneath the machined surface were measured with X-ray diffraction and electro-polishing techniques, and a chamfer tool at three different cutting speeds (250, 600 and 1000 m/min) to obtain the forces. The machining forces in both the cutting and thrust directions increases as the chamfer angle increases and decreases as the cutting speed increases.

orthogonal cutting; tool geometry; finite element method (FEM); dead metal zone