Fem HSM

ERC
NSM
1
Dr. Taylan Altan, Professor and Director
Partchapol (Jay) Sartkulvanich, Graduate Research Associate
Ibrahim Al-Zkeri, Graduate Research Associate
Engineering Research Center for Net Shape Manufacturing
The Ohio State University, Columbus, OH
(http://www.ercnsm.org)
CIRP- High Performance Cutting Conference, June 12-13, 2006
Vancouver, Canada
STATUS OF FEM MODELING
STATUS OF FEM MODELING
IN HIGH SPEED CUTTING
IN HIGH SPEED CUTTING
-
-
A Progress Report
A Progress Report
-
-
ERC
NSM
2
Main Research Activities:
[1] Determination of Flow Stress Data for
Finite Element Simulation
[2] Analysis of Burr Formation in Face
Milling of a Cast Aluminum Alloy
[3] Study of Hard Turning
PCBN Tool Edge Preparation
Cutting Force and Chip Formation
Residual Stresses
White Layer
[4] Study of Scaling Effects and Tool Coating
[5] Prediction of Tool Wear
[6] FEM Modeling of Roller Burnishing
Process
Current Focus of Research
Modeling of Machining
ERC
NSM
3
Process Simulation of Cutting
Controllable inputs
Material Properties
Plastic property (Flow stress)
Elastic property
- Youngs modulus
- Poissons ratio
Thermal property
- Thermal conductivity
- Specific heat capacity
- Thermal expansion
Contact Tribology
Friction condition
Interface heat transfer
Boundary conditions
Displacement boundary cond.
Thermal boundary cond.
...
Outputs
Cutting forces
Temperatures
Chip geometry
Surface integrity
Distribution of
Stress
Strain
Strain rate
Velocity
Nature of FEM code
(e.g. DEFORM
'
, Third Wave
'
)
Implicit/Explicit
Type of elements
Meshing/ Remeshing
...
Uncontrollable inputs
Numerical influence
Number of remeshing steps
Data interpolation algorithm
...
?
Neglected Variables
Machine Vibration
Tool Elastic Deflection
Dimensional Tolerances
...
ERC
NSM
4
0 500 2000 10
4
10
5
10
6
1
0
0

3
0
0

5
0
0

7
0
0

9
0
0

1
1
0
0
Strain rate [s
-1
]
T
e
m
p
e
r
a
t
u
r
e
[
C
]
Machining tests:
temperature:
240...900C
strain rate:
26,000...680,000s
-1
[1] Determination of Flow Stress
C 1,100 to 25 T , s 450 to up , 1 to 0
-1
= = =
&
High Speed Compression Tests (HSC):
Machining Tests (Slot Milling or
Orthogonal Turning):
SHPB with Hat-Shaped Sample:
Split Hopkinsons Pressure Bar (SHPB):
Methods Used for Flow Stress Determination
C 1,100 to 20 T , s 2,000 to up , 1 to 0
-1
= = =
&
C 1,000 to 20 T , s 10,000 to up , 0.5 to 0
-1
= = =
&
C 900 to 240 T
, s 680,000 to up , 1.5 to 5 . 0
-1
=
= =
&
Maekawa (SHPB):
temperature:
20...720 C
strain rate:
200...2000 s
-1
El Magd (SHPB):
temperature:
20...600 C
strain rate:
0.001...10000 s
-1
Conventional
compression
AISI 1045
At strain = 1.0
Example
Oxley (high
speed
compression):
temperature:
25...1100C
strain rate:
0...450 s
-1
ERC
NSM
5
Slot milling tests
r r
r r

cos F sin F F
sin F cos F F
y x t
y x c
=
+ =
F
x
: Force in x Direction
F
y
: Force in y Direction
F
t
: Thrust Force
F
c
: Cutting Force
r
: Rotation Angle
Geometrical Relations:
Forces in Slot Milling
ERC
NSM
6
Force data obtained from slot milling tests
-400
-200
0
200
400
600
[N]
1000
0 30 60 90 120 [deg] 180
rotation angle
C
u
t
t
i
n
g

f
o
r
c
e

i
n

X

a
n
d

y

d
i
r
e
c
t
i
o
n
EXP-max
EXP-min
EXP-AVE
AISI 1045
Rake = - 9.06 deg
f = 0.1 mm/rev
Vc = 300 m/min
w = 3 mm
uncoated
X Forces
Y Forces
Average of 20 Tool Rotations
-400
-200
0
200
400
600
[N]
1000
0 30 60 90 120 [deg] 180
rotation angle
C
u
t
t
i
n
g

f
o
r
c
e

i
n

X

a
n
d

y

d
i
r
e
c
t
i
o
n
EXP-max
EXP-min
EXP-AVE
EXP-max
EXP-min
EXP-AVE
AISI 1045
Rake = - 9.06 deg
f = 0.1 mm/rev
Vc = 300 m/min
w = 3 mm
uncoated
X Forces
Y Forces
Average of 20 Tool Rotations
ERC
NSM
7
Chip formation
=Shearangle
s =Averageplasticzonethickness
inprimaryzone
l =Lengthofshearplane
=Averageplasticzonethickness
insecondaryzone
t
2
=Chipthickness
Point of
Breakage
Chip
Root
Tool
Point of
Breakage
Chip
Root
Tool
Quick stop milling tests
feed
Workpiece
Tool
Metal Sheets
Rotation
Angle
rotation
feed
Workpiece
Tool
Metal Sheets
Rotation
Angle
rotation
Workpiece
Tool
Metal Sheets
Rotation
Angle
rotation
ERC
NSM
8
Flow Stress Determination Using Slot Milling Tests (ERC/NSM)
Slot Milling
Tests
E
x
p
e
r
i
m
e
n
t
a
l

T
a
s
k
s
Is Error
minimum?
OXCUT
Force Calculation
Slot Milling
C
o
m
p
u
t
a
t
i
o
n
a
l

T
a
s
k
s
Flow Stress
Equation
Experimental Measurements
- Cutting and thrust forces (F
C
, F
T
)
- Primary deformation zone (s/l)
- Secondary deformation zone (/t
2
)
OXCUT Predictions
- Cutting and thrust forces (F
C
, F
T
)
- Primary deformation zone ratio (s/l)
- Secondary deformation zone ratio (/t
2
)
Adjustment for
new-iterated
flow stress
No Yes
ERC
NSM
9
AISI 1018 (126-130 HB) carbon steel
AISI 1045 (93-96 HRB) carbon steel
AISI 1080 (85-88 HRB) bearing steel
AISI 8219 (90-93 HRB) bearing steel
P20 (30-32 HRC) mold steel
H13 (46-48 HRC) die steel
Data Determined with the Slot Milling Tests (ERC/NSM)
AA 356.0-T6, 7%SiC (59-67 HRB)
lost foam casting
AA 319 cast aluminum alloy
SS 348 stainless steel
Copper alloys
Inconel 718
Ti 17 titanium alloy
Flow Stress Equation Used is
a Modified Johnson & Cooks Equation
|
|
.
|
\
|
|
|
.
|
\
|
|
|
.
|
\
|
|
|
.
|
\
|
+ =
m
melt
n
T
T
C B
20
20
1
1000
ln 1

&
, where B, n, C and m are constants
ERC
NSM
10
MAterial DAtabase for Machining Simulation (MADAMS)
Summarize flow stress data collected from the literature and from
German researchers (in DFG program) in a MS-Access database
(Material list: www.ercnsm.org Machining R&D Update Material
Database for Machining Simulation (MADAMS))
MADAMS is web-based and accessible to researchers worldwide
with a password.
MADAMS is established with support from NSF, through Grant # DMI-
9821020 and DMI-0220924. (in cooperation with Universities of
Kentucky, Karlsruhe, Aachen, Hannover)
ERC
NSM
11
[2] Burr Formation in Face Milling of a
Cast Al Alloy A Case Study
A case study was conducted for face milling of cylinder
block and cylinder head surfaces, from cast Aluminum Alloy
A356-T6.
Objectives are to evaluate/compare tool performance and to
analyze burr formation based on tool edge and flank wear
geometries.
Tool Motion and Burr Locations in Face Milling
[Arai, 1987]
Tool rotation
ERC
NSM
12
T
Auto-feed
Auto-cut
T
Chip Formation
Simulation
using KontiSpan*
Simulation of
Burr Formation
Flow Stress Equation (through slot-milling tests):
Friction Assumption: Shear friction law with m = 0.6
|
|
.
|
\
|
|
.
|
\
|
|
|
.
|
\
|
|
|
.
|
\
|
+ =
62 . 1
144 . 0
20 585
20
1
1000
ln 0067 . 0 1 477
T

&
2 . 1 7 . 0
1
s 000 , 500 000 , 20

&
C 350 50
o
T
for
V
C
0 =
n
T
k
( )

=
T T h
n
T
k
( )
c
T T h
n
T
k =
int
V
C
0 =
n
T
k
( )

=
T T h
n
T
k
( )

=
T T h
n
T
k
T
*Developed at RWTH-Aachen
ERC
NSM
13
Workpiece: AA356-T6 Aluminum alloy (casting).
Tool: PCD, Rake angle = 0 deg.
Edge radius = 0.01 mm.
Cutting condition: Cutting speed =1433 m/min, feed rate = 0.25 mm/rev.
ERC
NSM
14
0.0
0.1
0.2
0.3
0 0.1 0.2 0.3 0.4 0.5
Flank Wear Width (VB, mm)
B
u
r
r

a
r
e
a

(
m
m
2
)
Rake angle = 0 degree
Rake angle = 20 degree
Worn-out
Sharp
The Effect of Rake Angle and Flank Wear
Worn insert generates 39% more burr area than the sharp insert.
Additional positive rake angle is effective for reducing burr at both
sharp and worn-out conditions. Tool fracture may occur at large
positive rake angles
Large positive rake angle is preferable if the tool life is reached by
flank wear rather than fracture at the tool tip.
ERC
NSM
15
Tool with Uniform Edge
Hone Radius
Tool with Variable Edge
Hone Radius
Tool Edge Radius (m) Effective Uncut
Chip Thickness at 90
rotation angle (mm)
Tool
Section
25.4 25.4 0.254 C-C
20.0 25.4 0.200 B-B
4.2 25.4 0.042 A-A
Variable Edge
Honed Tool
Uniform Edge
Honed Tool
A B
C
A
B
C
Evaluation of the Performance of Variable Edge Honed Tool
A procedure was established to emulate 3D face milling with
a simplified 2D orthogonal cutting model
Tool cross sections in the chip flow direction are considered for
2D simulations.
ERC
NSM
16
3D Face Milling Simulations
Two 3D face-milling simulations were
conducted for the tools at sharp and
worn-out conditions.
Workpiece was assumed as a small
section near the exit where the
maximum uncut chip load is located.
High mesh density was defined for
regions near the tool corner radius
and at the exit of burr.
For face milling simulation of the worn
insert, experimental flank wear
geometries were included in a solid
model of the insert.
Tool
Workpiece
Tool
Workpiece
Tool rotation
Tool feed
3D View
ERC
NSM
17
0.00
0.02
0.04
0.06
0.08
0.10
-0.6 -0.4 -0.2 0.0
3D Face Milling
Simulation
2D Orthogonal
Cutting Simulation
Cutting plane for a side view
Comparison of burr profile between 3D (side view)
and 2D simulations
-0.1
0
0.1
0.2
0.3
-0.6 -0.5 -0.4 -0.3 -0.2 -0.1 0 0.1
Milling with sharp insert
Milling with worn insert
Comparison of burr profile between milling with
sharp and worn inserts
Burr
height
Burr
width
Burr
thickness
Definition of burr geometry
Burr thickness (mm)
B
u
r
r

h
e
i
g
h
t

(
m
m
)
Burr thickness (mm)
B
u
r
r

h
e
i
g
h
t

(
m
m
)
ERC
NSM
18
Effective Strain
Possible fracture
Effective Strain Effective Strain
Possible fracture
Highly stretching region indicates possible fracture
ERC
NSM
19
Summary of the Findings/ Recommendations
Tool insert with larger flank wear width generates more burrs.
Larger positive rake angle (within limits) is desirable for burr
reduction if the tool life is determined by flank wear rather
than tool fracture.
There is no significant difference in burr formation between
uniform and variable edge honed tools. However, variable
edge honed tool indicates potential increase in tool life and
slowing down of burr generation rate.
Reduction of the wiper length of the insert can contribute to
burr reduction.
The predicted burrs from 3D simulation are much smaller
than the burrs seen in experiments. The difference could be
caused by the accumulation of burrs as result of several
subsequent cutting passes. Unless burrs fracture, the larger
number of repetitive cutting passes can result in larger burrs.
ERC
NSM
20
[3] PCBN Tool Edge Preparation in
Hard Turning A Case Study
Introduction
Goal: Predicting the best PCBN tool edge preparation
Challenges of FEM
Model chip formation accurately: Be able to model
serrated chip formation
Accurate flow-stress and friction models: Can provide the
results close to experiments
ERC
NSM
21
Tool insert TPG-432T, mounted on
CTFPL-163D tool-holder
Chamfer angle (): 15 to 30 deg
Edge hone (r): 5 to 20 micron
Rake angle (): 5 deg
Clearance angle (): 6 deg
Chamfer width (w): 0.2 mm
PCBN Grade: Low CBN
Work Material: 100Cr6 (AISI E52100) 60
HRC, Through-hardened
Cutting Condition
Cutting speed (V
c
): 91 to 182 m/min
Feed rate (f): 0.076 and 0.152 mm/rev
Width of cut: 3.16 mm
f
V
c
Workpiece
Cutting
Tool
Tool, Workpiece and Cutting Condition
ERC
NSM
22
( )
0
1 ln 1
m
n
r
m r
T T
A B C
T T
(
| | | |
( = + +
| |
(
\ . \ .

&
&
( ) ( ) ( )
ln( )
n m
C F HRC G HRC D A B T
( (
= + + +

&
No inherent surface-crack initiation/propagation mechanism in
the cutting simulation
Flow stress model for AISI 52100 from machining
(Huang, 2002) and compression tests (Umbrello, 2004)
Friction Condition (Zorevs model / m = 1, = 0.35)
Huangs model (for ranges: > 1.0, > 10
4
, T = 300 to 500 C):
&
Umbrellos model (for ranges: 1.0, 10
2
, T = 20 to 300 C
and 500 to 1200 C):

&
ERC
NSM
23
Serrated chip formation and
mesh distribution in FEM
simulation of hard turning
Temperature distributions
during hard turning
ERC
NSM
24
Summary of the Findings
The predicted (FEM) and measured forces are close (20% and
9% in predicting cutting and thrust forces, respectively).
Their variations with chamfer angle and cutting speed are
predicted.
The tool chamfer angle has the largest influence on thrust
forces.
Although similar chip morphology (i.e. serrated chip) is
predicted, the exact dimensions of predicted serrated chips
do not match the experiment.
Cyclic (16% more than average) Von-Mises stresses are
generated due to the serrated chipping.
Simulations must be improved to predict the residual
stresses.
ERC
NSM
25
Current Status of
FEM Modeling of Cutting
FEM Models of Cutting have been developed for various
studies and applications (e.g. force prediction, chip formation,
tool stress, burr formation, tool wear, tool coating, etc.)
Although several material testing methods have been
proposed,
the determination of flow stress data is not satisfactory.
Cutting force and chip thickness can be well predicted with
FEM. However, predicted thrust force from FEM is always
lower than the experiments, especially for positive rake tool.
FEM is good for predicting trends but needs further
improvements for quantitative predictions of
Tool-chip contact length and consequent crater wear.
Onset of serrated chip formation and serration frequency
Residual stresses in machined surface
Most FEM studies have focused on 2D orthogonal cutting.
ERC
NSM
26
Major Challenges for Practical
Application of FEM in Machining
Robust methodology for determining flow stress
(inverse analysis using cutting tests / determination
of properties of surface layers)
Prediction of tool wear and residual stresses
(elastic deformation of workpiece, tool and machine
/ microstructural variations on machined surface)
Parallel processing for practical use of 3D FEM
modeling (partially achieved)
Others?
ERC
NSM
27
Animations of FEM Process Simulations
FEM Analysis of 3-D Turning Process (2 of 2)
Material: AISI 8219 (ERC flow stress model)
Cutting insert: TNMA432 uncoated K68 carbide
Cutting speed: 320 m/min
Feed rate: 0.25 mm/rev
Depth of cut: 1.5 mm
Normal rake angle: -7 deg
Inclination angle: -7 deg
Lead angle: 0 deg
Effective stress Mesh model
ERC
NSM
28
Animations of FEM Process Simulations
2-D Simulation of Serrated Chip Formation in HSC
20 C
650 C
Workpiece Material: AISI 1045 (Oxley)
Tool Material: Uncoated Carbide
Cutting Speed: 150 m/min
Edge Radius: 0.1 mm
Rake Angle: -7 deg, Depth of Cut: 1 mm
Fracture criterion: Normalized C & L
ERC
NSM
29
Questions ??
Questions ??

Fem HSM

Uploaded by

Copyright:

Available Formats

Fem HSM

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Fem HSM

Uploaded by

Copyright:

Available Formats

ERC

You might also like