AND
TOOL EDGE RADIUS EFFECT ON MICRO-TURNING
PROCESS
USING FEM SOFTWARE
EXTENDED ABSTRACT
Submitted by
Sugan Durai Murugan V
ME09B056
CONTENT
PAGE NO
1. INTRODUCTION
3. BOUNDARY CONDITIONS
3.3. MOVEMENT
4. RESULTS ON TURNING
10
7. CONCLUSION
11
8. REFERENCES
13
1. INTRODUCTION
Understanding of the basics of metal cutting processes through the experimental studies has many
limitations. Researchers find this investigation through experiments a very time consuming and
expensive work. Using the capabilities of Finite Element Analysis, metal cutting modeling and
simulation provides an alternative and easier way for better understanding of machining process
under different cutting conditions with less number of experiments. Turning is one of the widely
used metal cutting manufacturing technique in the industry world and there are lots of studies going
on to investigate this complex process. Several models have been presented in the past with different
assumptions. In this project , application of Finite Element Method is used in simulating the effect
of cutting tool geometry and cutting speed on effective stress, cutting force and temperature changes.
DEFORM is the simulation tool used in this study. DEFORM is a Finite Element Method (FEM)
based process simulation system designed to analyze various forming processes used by metal
forming applications. It is available in both Lagrangian (Transient) and arbitrary Lagrangian and the
Eulerian (ALE Steady-State) modeling. Additional, the software is currently capability of SteadyState function and it is required of running a transient simulation previous to steady state cutting
simulation.
, , = + + [ ( ) ]
(1)
Where is the equivalent plastic strain, is the plastic strain-rate, and A, B, C, n, and m are
material constants. The strain-rate and temperature are normalized for simplicity in representing the
model. The normalized strain-rate and temperature in equation (1) are defined as
=
( )
, = (
(2)
Where is the effective plastic strain-rate of the quasi-static test. is a reference temperature, and
is a reference melt temperature.
A simplified illustration of the plastic deformation for the formation of a continuous chip when
machining a ductile material is given in Figure 1.1.
There are two deformation zones [2] in this simplified model a primary zone and a
secondary zone. The primary plastic deformation takes place in a finitely sized shear zone. The work
material begins to deform when it enters the primary zone from lower boundary CD, and it continues
to deform until it reaches the upper boundary EF. Even after exiting from the primary deformation
zone, some material experiences further plastic deformation in the secondary deformation zone only
on a smaller scale.
(3)
(4)
()
(5)
In a thermo-mechanically coupled model, a huge amount of heat energy will be generated due to
large deformations and temperature of the model will increase during the process. The rate of
specific volumetric flux due to plastic work is given by the following equation,
=
(6)
Where, f is the fraction of plastic work converted into heat, and is the rate of plastic work. Heat
generated due to friction is given by the equation,
(7)
Where, Ffr is the friction force, Vr is the relative sliding velocity between tool and chip. Due to the
change in temperature, thermal material laws are needed to be defined to adapt the elastic-plastic
model to the new temperature conditions. Convective heat transfer at the tool-work piece interface,
thermal expansion, and heat capacity is defined for range of temperatures.
3. BOUNDARY CONDITIONS
3.1. FRICTION BETWEEN TOOL AND WORK PIECE
The dependence of friction parameter on the cutting conditions can be explained by considering
the distribution of frictional shear stress on the rake face of the tool. Over the length h1, the normal
stress is very high and the metal adheres to the rake face, the friction stress is independent of the
normal. This region is called sticking region. On the length h2, smaller normal stresses exist and the
usual condition of sliding friction applies. This region is called sliding region. Based on this, two
types of friction models were developed called Coulomb type and Shear type.
(8)
Where m is the shear friction factor needs to be estimated and given as input, is the
shear flow stress of the chip at the primary zone and is the frictional stress.
The coulomb friction model is given by
(9)
Where is the coulomb friction factor needs to be estimated and given as input, is the normal
4. RESULTS
AISI 1045 has been taken as the elastic-plastic work piece and Tungsten carbide (WC) is used as the
rigid cutting tool. The cutting parameters used for the simulation are
1) Depth of cut (d) 0.5 mm
2) Feed rate (f) 0.3 mm
3) Environment Temperature 20
Figure 4.1: Effective stress vs. Time under different cutting speeds
To find an average effective stress value over varying cutting speed, a constant stroke length is
taken as a reference. A stroke length of 0.35 mm is taken to average the stress values. The cutting
time to reach this stroke length is also noted. Table 1 shows the average Effective stress values over
different cutting speed.
Cutting
Cutting time
(m/min)
(MPa)
( e-5 sec)
100
1432.12
20.6
150
1346.57
13.7
250
1404.84
8.0
Table 1:
Cutting
Speed
(m/min)
100
734.36
0.277
150
750.25
0.376
250
771.50
0.605
Table 2:
Maximum Temperature
angle()
(0C)
(kN)
50 , 70
585
0.925
00, 70
514
1.178
-50, 70
724
1.462
Table 3:
Micro turning is one type of micromachining process which uses a solid tool and its material
removal process is almost similar to conventional turning operation. In recent years, researchers have
explored a number of ways to improve the micro turning process performance by analyzing the
different factors that affect the quality characteristics. Unlike conventional macro-machining
processes, micro-machining displays different characteristics due to its significant size reduction.
Therefore size effect [6] is defined as the effect due to the small ratio of the depth of cut to the tool
edge radius. Often, the edge radius of the tools is relatively larger than the chip thickness to prevent
plastic deformations or breakage of the micro-tools. In contrast to the conventional sharp-edge
cutting model, chip shear in micro-machining occurs along the rounded tool edge.
Tool edge radius is an important parameter for surface quality in micromachining. Under
certain machining practices, cutting tip of the tool is strengthened with an edge radius for higher tool
life. Assumption of famous shear plane model in conventional machining is acceptable only when
undeformed chip thickness a is very much larger than the tool edge radius r, by at least three
orders of magnitude. This study is mainly focused on the behavior of chip formation in the transient
stages of several micro seconds where tool deformation is not accounted for.
In this study, the analysis of micro machining with FEM is performed under plane strain
condition using the explicit dynamic algorithm and the ALE as the solution method similar to that
macro turning process we have done already. The work piece used here is AISI 4340 and tool is
Tungsten Carbide. The tool radius varies from 1m to 5 m to illustrate the tool edge radius effect.
The depth of cut is kept constant at 2 m. Cutting speed is also kept constant at 1666.67 mm/s.
d) R= 3m
c) R= 2m
b) R= 1m
f) R= 5m
e) R= 4m
and extending towards the turning point of the chip free boundary, which is known as the primary
deformation zone in the conventional turning model. But as the radius increases the deformation
zone gets larger, and material in the vicinity of the rounded tool edge undergoes severe plastic
deformation. The increase in size and thickness of the plastic zone is due to the merger of the
primary and secondary deformation zone. Critically at r=5m, the deformation zone is highly
localized in front of the rounded tool edge which could lead to the changes in chip formation
behavior.
a) R= 0
b) R= 1
c) R= 2
d) R= 3
e) R= 4
f) R= 5
Figure 6.2: Von-Mises Effective stress distribution for various tool radii.
turning as shown in Figure 6.3 .Due to this increase in negative rake angle, the cutting forces
increases as the tool radius increases. Figures 6.4 and 6.5 showing cutting forces and thrust forces for
tool radii r=1,3,5 m.
Figure 6.3: Formation of negative rake angle at the rounded tool edge.
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Figure 6.4: Thrust force vs. time for tools with different edge radius
Figure 6.5: Cutting force vs. time for tools with different edge radius
7. CONCLUSION
1) As cutting speed increases, the effective stress on the chip formed decreases momentarily and
then increases, indicating i.e. in a allowable cutting speed range for which the effective stress
can attain a minimum value.
2) The temperature of the chip formed in turning of AISI 1045 increases with increase in cutting
speed. Therefore higher the cutting speed, larger the coolant flow to maintain the
temperature.
3) Machining with a negative rake angle tool results in higher cutting force and temperature, but
than positive rake angle.
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8. REFERENCES
[1] G.R.JOHNSON, W.H. COOK, 1983, A constitutive model and data for metals subjected to
large strains, high strain rates and high temperatures, Proceedings of the 7th International
Symposium on Ballistics, The Hague, The Netherlands, 541- 547.
[2] OXLEY, P.L.B., 1989, Mechanics of Machining, An Analytical Approach to Assessing
Machinability, Halsted Press, John Wiley & Sons Limited, New York, 1989.
[3] SHAW, M.C. and MAMIN, P.A., Friction characteristics of Sliding Surfaces undergoing subsurface plastic flow, Journal of Basic Engineering, 1960.
[4] ERNST, H., Machining of Metals, American Society for Metals, 1938.
[5] K.S.WOON, M.RAHMAN, F.Z.FANG, K.S.NEO, K.LIU, Investigations of tool edge radius
effect in micromachining: A FEM simulation approach, Journal of materials processing technology,
2008.
[6] J.CHAE, S.S.PARK, T.FREIHEIT, Investigation of micro-cutting operations, International
journal of Machine tools and manufacture, 2006.
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