Abstract
This contribution presents three-dimensional turning operation simulations exploiting the capabilities of finite element (FE) based software Abaqus/Explicit. Coupled temperature-displacement simulations for orthogonal cutting on an aerospace grade aluminum alloy AA2024-T351 with the conceived numerical model have been performed. Numerically computed results of cutting forces have been substantiated with the experimental data. Research work aims to contribute in comprehension of the end-burr formation process in orthogonal cutting. Multi-physical phenomena like crack propagation, evolution of shear zones (positive and negative), pivot-point appearance, thermal softening, etc., effecting burr formation for varying cutting parameters have been highlighted. Additionally, quantitative predictions of end burr lengths with foot type chip formation on the exit edge of the machined workpiece for various cutting parameters including cutting speed, feed rate, and tool rake angles have been made. Onwards, to investigate the influence of each cutting parameter on burr lengths and to find optimum values of cutting parameters statistical analyses using Taguchi’s design of experiment (DOE) technique and response surface methodology (RSM) have been performed. Investigations show that feed has a major impact, while cutting speed has the least impact in burr formation. Furthermore, it has been found that the early appearance of the pivot-point on the exit edge of the workpiece surface results in larger end-burr lengths. Results of statistical analyses have been successfully correlated with experimental findings in published literature.
Highlights
Machining is one of the oldest and most commonly employed manufacturing processes to shape the materials with a high dimensional accuracy and surface finish
Invaluable experimental and numerical efforts have been made in this context to comprehend burr formation mechanisms [2,3], model and predict burr sizes [4,5,6], control burr formation by tool geometry selection and tool path planning [7,8,9,10], and workpiece geometry design [11], etc
A finite element based orthogonal cutting model for turning process has been developed in the Abaqus/Explicit software
Summary
Machining is one of the oldest and most commonly employed manufacturing processes to shape the materials with a high dimensional accuracy and surface finish. Statistical investigations, to evaluate the influence of cutting parameters (input factors or controllable factors) including cutting speed (VC ), feed rate (f ), and tool rake angle (γ) on the computed results of burr lengths (response) have been performed. In this perspective, initially, a finite element based orthogonal cutting model for turning process has been developed in the Abaqus/Explicit software. After acquiring the satisfactory validation of the numerical model, further FE-analyses considering material plasticizes, fractures occur, and chips separates from the workpiece and eventually a new various combination of cutting parameters have been performed and end-burr lengths are computed. Figure 1. 3D geometrical model and boundary conditions for orthogonal machining
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