Finite element simulation of machining AISI 1045 steel using uncoated carbide tool
In recent years, finite element methods (FEM) have become widely used in research and industrial applications because of the advancements in computational efficiency and speed. FEM is a useful tool for the analysis of metal cutting process where this method provide better prediction of process va...
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| Main Author: | |
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| Format: | Thesis |
| Language: | English English English |
| Published: |
2012
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| Subjects: | |
| Online Access: | http://eprints.uthm.edu.my/1994/1/24p%20NABILA%20AFIF%20MOHMD%20ARIFIN.pdf http://eprints.uthm.edu.my/1994/2/NABILA%20AFIF%20MOHMD%20ARIFIN%20COPYRGHT%20DECLARATION.pdf http://eprints.uthm.edu.my/1994/3/NABILA%20AFIF%20MOHMD%20ARIFIN%20WATERMARK.pdf |
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| Summary: | In recent years, finite element methods (FEM) have become widely used in research
and industrial applications because of the advancements in computational efficiency
and speed. FEM is a useful tool for the analysis of metal cutting process where this
method provide better prediction of process variables whereas interaction of the tool
and the chip can also be examined. Much cutting force models have been developed
to predict the machining parameter. Most focus mainly on dry conditions even
though coolants are widely used in practical machining. Research for modeling of
minimal quantity lubricant (MQL) conditions is scarce and not really established.
The use of coolants in machining makes it very difficult to determine the friction
coefficient at the tool-chip interface. Hence, a better understanding of friction
modeling is required in order to produce more realistic finite element models of
machining process. In this study, a rigorous investigation on the role played by the
implemented friction model within a 2D simulation was carried out. The simulation
tool used for the purpose of this study is DEFORM2D. DEFORM 2D can simulate
large deformation accompanied by elastic, plastic, thermal and friction effects. The
simulation results on cutting forces and temperature were compared with
experimental measurement in order to verify wether it is possible to identify the best
friction model and indicate the consistency and accuracy of the results when
conducting the comparison. From the result, it shows that friction models affect
predicted result for both cutting force and temperature in dry and MQL conditions. |
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