modelling thermal effects in machining by finite element methods authors andrea bareggi (presenter)...
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MODELLING THERMAL EFFECTS IN MACHINING BY FINITE ELEMENT
METHODS
Authors Andrea Bareggi (presenter) Andrew TorranceGarret O’Donnell
IMC
200
7
Department of Mechanical and Manufacturing Engineering
The University of Dublin
Trinity College
Trinity College Dublin
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Introduction
FE modelling for metal cutting• Stress, strain, strain rate predictions• Temperature distribution in the primary,
secondary and tertiary sub-cutting zones
Trinity College Dublin
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• Cutting forces, plastic deformation (shear angles and chip thickness)
• Temperature in the workpiece, chip and tool
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Commercial packagesTrinity College Dublin
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ABAQUS
• Manual design of geometry, meshing and boundary condition setting
• No material library, but materials can be defined in detail
• Partial support in adaptive remeshing
• Good control of the solver
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Commercial packagesTrinity College Dublin
IMC
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ADVANTEDGE
• Very efficient interface to rapidly configure a model, tool library is provided
• Extensive material library
• Uses adaptive remeshing, but controls can not be modified
• Not suitable for customising control functions
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IMC
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Commercial packagesTrinity College Dublin
DEFORM 3D
• Built in “wizard” for machining
• Good material library and comprehensive material editor
• Uses adaptive remeshing, good control of meshing parameters
• The user can chose the solver and minimal control is permitted
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Problem formulationTrinity College Dublin
IMC
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• Incremental Lagrangian formulation
• Implicit integration method
• Solver with sparse matrix
• Direct method
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Problem formulationTrinity College Dublin
• Cutting speed: 270m/min• Feed: 0.06mm/rev• Depth of cut: 0.5mm• Effective rake angle = 0°
nose radius = 0.2mm• Cooling method: air jet• AISI 1020 steel
workpiece,1.5 mm of length, plastic
• WC insert with reduced heat capacity, rigid
workpiece
insert
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Thermal boundary conditionsTrinity College Dublin
• No cooling, natural convection, h=20 W/m²/K
• Air jet, overhead position, h=2000 W/m²/K
• Air jet, interface position, h=2000 W/m²/K
IMC
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overhead
interface
Interface nozzle dir.
Overhead nozzle dir.
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ResultsTrinity College Dublin
IMC
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• Steady state condition: workpiece, interface, insert
• Temperature prediction: workpiece, chip and interface
Chip temperature(416°C)
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ResultsTrinity College Dublin
IMC
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feed=0.06mm/revdepth=0.5mmspeed=270m/min
Maxworkpiecetemp. (°C)
Interface temp. (°C)
Chip temp. (°C)
CuttingForce (N)
Dry cutting 737 710 416 93Air jet cooling,
overhead721 627 389 92
Air jet cooling, interface
727 648 408 95
• Reduction of interface temperature• Best cooling in overhead position• No influence on the cutting force
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ResultsTrinity College Dublin
IMC
200
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• Prediction of gradient temperature within the insert
• Developing of experimental techniques for investigating temperature
Temp (°C)
A=20
B=88
C=156
D=225
E=293
F=361
G=429
H=498
I=566
J=634
K=702
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ConclusionTrinity College Dublin
IMC
200
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• Results consistency: analytical results, ADVANTEDGE simulations, preliminary temperature measurements
• Finite Elements: cost saving in experimental work, process insight in cooling and lubricating method
• 3D modelling techniques under development, in particular with cooling
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Further researchTrinity College Dublin
IMC
200
7
• Refinement of the model, estimation of the heat transfer coefficients, improved approach to jet modelling
• Simulation with different workpiece materials and cutting conditions
• Experimental validation, currently ongoing
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Literature & AcknowledgementsTrinity College Dublin
IMC
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•N.A. Abukhshim, P.T. Mativenga, M.A. Sheikh, Heat generation and temperature prediction in metal cutting: A review and implications for high speed machining, International Journal of Machine Tools & Manufacture 46 (2006) 782–800•J.D. Gardner, A.Vijayaraghavan, D.A. Dornfeld, Comparative Study of Finite Element Simulation Software, eScholarship Repository, University of California, Copyright c 2005 by the authors•T. O’Donovan, Fluid flow and heat transfer of an impinging air jet, Phd. Thesis, Mechanical & Manufacturing Engineering, Trinity College Dublin, 2005•D. Umbrello, L. Filice, S. Rizzuti, F. Micari, On the evaluation of the global heat transfer coefficient in cutting, International Journal of Machine Tools & Manufacture 47 (2007) 1738–1743
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Literature & AcknowledgementsTrinity College Dublin
IMC
200
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AcknowledgementsChristian E. Fischer, Ph.D., PE, (Scientific Forming Technologies Corporation, Columbus, Ohio, USA)
Questions?