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Single Point Turning of Materials Using FEM Simulations

Single Point Turning of Materials Using FEM Simulations . Presented by: Chris Wells Brant Liou. Single Point Turning of Materials Using FEM Simulations. Background Information on Single-Point Turning Elements of Single Point Turning Material Cases: Grade 410 Stainless Steel (Annealed)

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Single Point Turning of Materials Using FEM Simulations

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  1. Single Point Turning of Materials Using FEM Simulations Presented by: Chris Wells Brant Liou

  2. Single Point Turning of Materials Using FEM Simulations • Background Information on Single-Point Turning • Elements of Single Point Turning • Material Cases: • Grade 410 Stainless Steel (Annealed) • Brass Material (As-Sintered) • Aluminum Alloy Al2024-T3511 (Cold-Drawn) • Inconel 718 • FEM Model setup • Depth of Cut • Feed • Speed • Rake Angle • Tool Material • FEM Results • Theories & Calculations • Conclusion

  3. Elements of Single Point Turning (Orthogonal) • Machining angles: • Rake angle, α • Friction Angle, λ • Shear Plane Angle, φ

  4. Material Cases • AISI Grade 4130 Alloy (Medium Carbon) • Hardness = 375 Bhn • Yield Strength = 883 MPa

  5. Material Cases • Type C37700 Brass Material • Hardness = 81 Bhn • Yield Strength = 138 MPa

  6. Material Cases • Al 2024-T3511 • Hardness = 38 to 50 Bhn • Yield Strength = 170MPa

  7. Material Cases • Iconel 718 • Hardness = 454 Bhn • Yield Strength = 1103MPa

  8. FEM Results • AISI Grade 4130 Alloy (Medium Carbon) • Input Parameters: • Depth of Cut = 4 mm • Feed = 0.4 mm/rev • Speed = 100 m/min • Rake Angle = 0° • Cutting Radius = 0.02 mm • Relief Angle = 10° • Cutting Tool – HSS-General Click on the image to animate the results

  9. FEM Results AISI Grade 4130 Alloy (Medium Carbon)Rake Angle 00 Max Shear Stress 4623.12 MPa AISI Grade 4130 Alloy (Medium Carbon)Rake Angle 450 Max Shear Stress 5996.24 MPa

  10. FEM Results AISI Grade 4130 Alloy (Medium Carbon) Rake Angle 00 Cutting & Thrust Forces AISI Grade 4130 Alloy (Medium Carbon)Rake Angle 450 Cutting & Thrust Forces

  11. FEM Results AISI Grade 4130 Alloy (Medium Carbon)Rake Angle 00 Max Von Mises Stress 8060.08 MPa AISI Grade 4130 Alloy (Medium Carbon)Rake Angle 450 Max Von Mises Stress 12725.1 MPa

  12. FEM Results AISI Grade 4130 Alloy (Medium Carbon)Rake Angle 00 Max Temperature 603.08 AISI Grade 4130 Alloy (Medium Carbon)Rake Angle 450 Max Temperature 516.749

  13. FEM Results AISI Grade 4130 Alloy (Medium Carbon)Rake Angle 00 Max Pressure 5315.14 AISI Grade 4130 Alloy (Medium Carbon)Brass Rake Angle 450 Max Pressure 15906.1

  14. FEM Results • Type C37700 Brass • Input Parameters: • Depth of Cut = 4 mm • Feed = 0.4 mm/rev • Speed = 100 m/min • Rake Angle = 0° • Cutting Radius = 0.02 mm • Relief Angle = 10° • Cutting Tool – HSS-General Click on the image to animate the results

  15. FEM Results Type C37700 Brass Rake Angle 00 Max Shear Stress 2044.74 MPa Type C37700 Brass Rake Angle 450 Max Shear Stress 1598.75

  16. FEM Results Type C37700 Brass Rake Angle 00 Cutting & Thrust Forces Type C37700 Brass Rake Angle 450 Cutting & Thrust Forces

  17. FEM Results Type C37700 Brass Rake Angle 00 Max Von Mises Stress 3928.02 MPa Type C37700 Brass Rake Angle 450 Max Von Mises Stress 2896.23

  18. FEM Results Type C37700 Brass Rake Angle 00 Max Temperature 358.41 Type C37700 Brass Rake Angle 450 Max Temperature 305.29

  19. FEM Results Type C37700 Brass Rake Angle 00 Plastic Strain Type C37700 Brass Rake Angle 450 Plastic Strain

  20. FEM Results Type C37700 Brass Rake Angle 00 Max Pressure 3668.05 Type C37700 Brass Rake Angle 450 Max Pressure 1797.33

  21. FEM Results • Al 2024-T3511 (Cold Drawn) • Input Parameters: • Depth of Cut = 4 mm • Feed = 0.4 mm/rev • Speed = 275 m/min • Rake Angle = 0° • Cutting Radius = 0.02 mm • Relief Angle = 10° • Cutting Tool – HSS-General Click on the image to animate the results

  22. FEM Results Al 2024-T3511 Rake Angle 150 Max Temp 334 Deg C Al 2024-T3511 Rake Angle -150 Max Temp 350 Deg C

  23. FEM Results Al 2024-T3511 Rake Angle 150 Plastic Strain Al 2024-T3511 Rake Angle -150 Plastic Strain

  24. FEM Results Al 2024-T3511 Rake Angle -150 Cutting & Thrust Force Al 2024-T3511 Rake Angle 150 Cutting & Thrust Force

  25. FEM Results Al 2024-T3511 Rake Angle 150 Max Von Mises Stress 3573 MPa Al 2024-T3511 Rake Angle -150 Max Von Mises Stress 2950 MPa

  26. FEM Results Al 2024-T3511 Rake Angle 150 Max Shear Stress 1887 MPa Al 2024-T3511 Rake Angle -150 Max Shear Stress 1589 MPa

  27. FEM Results Al 2024-T3511 Rake Angle 150 Max Pressure 3120 MPa Al 2024-T3511 Rake Angle -150 Max Pressure 2261 MPa

  28. FEM Results • Inconel 718 • Input Parameters: • Depth of Cut = 4 mm • Feed = 0.25 mm/rev • Speed = 23 m/min • Rake Angle = 0° • Cutting Radius = 0.02 mm • Relief Angle = 10° • Cutting Tool – HSS-General Click on the image to animate the results

  29. FEM Results Inconel 718 Rake Angle -150 Max Temp 814 Deg C Inconel 718 Rake Angle 150 Max Temp 820 Deg C

  30. FEM Results Inconel 718 Rake Angle 150 Plastic Strain Inconel 718 Rake Angle -150 Plastic Strain

  31. FEM Results Inconel 718 Rake Angle -150 Cutting & Thrust Force Inconel 718 Rake Angle 150 Cutting & Thrust Force

  32. FEM Results Inconel 718 Rake Angle 150 Max Von Mises Stress 14526 MPa Inconel 718 Rake Angle -150 Max Von Mises Stress 6852 MPa

  33. FEM Results Inconel 718 Rake Angle 150 Max Shear Stress 7305 MPa Inconel 718 Rake Angle -150 Max Shear Stress 2845 MPa

  34. FEM Results Inconel 718 Rake Angle 150 Max Pressure 15427 MPa Inconel Rake Angle -150 Max Pressure 11186 MPa

  35. FEM Results HSS HSS • Inconel 718 • Input Parameters: • Depth of Cut = 4 mm • Feed = 0.25 mm/rev • Speed = 23 m/min • Rake Angle = 0° • Cutting Radius = 0.02 mm • Relief Angle = 10° • Cutting Tool – HSS-General • Cutting Tool – Carbide General Carbide Carbide

  36. Theories & Calculations • Friction Angle Calculation: • Al 2024-T3511 Rake Angle 00 • tan -1(0.25)=14 • λ = 140

  37. Theories & Calculations

  38. Theories & Calculations (Cont.)

  39. Conclusion

  40. References • Metal Machining - Theory and ApplicationsBy: Childs, T.H.C.; Maekawa, K.; Obikawa, T.; Yamane, Y.   © 2000 Elsevier • M.C. Shaw, Metal Cutting Principles, 2nd ed., Oxford U.P., New York, 2005 • Third Wave AdvantEdge User Manual

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