رسالة ماجيستير بعنوان Simulation of Orthogonal Metal Cutting by Finite Element Analysis
منتدى هندسة الإنتاج والتصميم الميكانيكى
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 رسالة ماجيستير بعنوان Simulation of Orthogonal Metal Cutting by Finite Element Analysis

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عدد المساهمات : 14465
التقييم : 23411
تاريخ التسجيل : 01/07/2009
العمر : 29
الدولة : مصر
العمل : مدير منتدى هندسة الإنتاج والتصميم الميكانيكى
الجامعة : المنوفية

مُساهمةموضوع: رسالة ماجيستير بعنوان Simulation of Orthogonal Metal Cutting by Finite Element Analysis   السبت 16 أغسطس 2014, 11:59 am

أخوانى فى الله
أحضرت لكم رسالة ماجيستير بعنوان
Simulation of Orthogonal Metal Cutting by Finite Element Analysis

BY
HALİL BİL
IN PARTIAL FULFILLMENT OF THE REQUIREMENTS FOR THE DEGREE OF
MASTER OF SCIENCE
IN THE DEPARTMENTOF MECHANICAL ENGINEERING


ويتناول الموضوعات الأتية :

Abstract   iii
Öz   v
Dedication   vii
Acknowledgements   viii
Table of Contents  ix
List of Tables xii
List of Figures  xiii
List of Symbols and Abbreviations xviii
CHAPTERS
1  INTRODUCTION  1
11  Introduction   1
12  Aimand Scope of the Study  4
13  Finite Element Models and Experiments 5
14  Content of this Study 6
2  LITERATURE SURVEY  7
21  Introduction   7
22  Chip Formation and Nomenclature 7
23  Shear Zone Models  15
24  Shear Angle Relationships  16
241  Merchant's Relationship    17
ix
242  Lee and Shaffer's Relationship 18
243  Oxley's Relationship  18
244  Other Relationships18
25  Friction on the Rake Face of a Cutting Tool19
26  The Shear Stress in Shear Zone During Metal Cutting21
27  Numerical Approach  24
271  Steady State Solutions 24
272  Solutions for Continuous Chip Formation 29
273  Solutions for Transient Chip Formation  29
274  Solutions for Transient and Continuous Chip Formation  31
28  Conclusion  38
3  EXPERIMENTAL WORK39
31  Introduction 39
32  Orthogonal Cutting40
33  Workpiece Material41
34  Test Setup 42
35  Cutting Experiments Performed in This Work 49
36  Compression Test 50
4  NUMERICAL MODEL OF ORTHOGONAL METAL CUTTING 53
41  Introduction 53
42  Finite Element Models 54
421  Finite Element Model with MSCMarc54
422  Finite Element Model with Deform2D63
423  Finite Element Model with Thirdwave AdvantEdge66
43  Comparison of Finite Element Models71
x
5  RESULTS AND COMPARISON 72
51  Introduction 72
52  Comparison with Analytical Solutions75
53  Comparison of Chip Geometry77
54  Comparison of Cutting Forces 92
55  Comparison of Thrust Forces96
56  Comparison of Simulation with the Experimental Results from
Literature 100
6  DISCUSSION AND CONCLUSION104
61  Introduction 104
62  Effect of Friction 105
63  Effect of Material Modeling  106
64  Effect of Chip Separation Criterion  107
65  Computational Aspects108
66  Conclusion  109
67  Recommendation for Future Work  110
References  112
xi
LIST OF TABLES
31  Chemical composition of C15 steel inweight percent41
32  Mechanical and thermal properties ofthe workpiece
material, C15 steel 42
33  Specifications of the Topcon Universal Measuring Microscope 47
34  Cutting conditions at which experiments were performed 49
41  Comparison of three commercial codes 71
51  Simulations were done under fourdifferent cutting conditions 72
52  Experimental results of chip geometry parameters 78
53  Chip geometry results with MSCMarc  78
54  Chip geometry results fromDeform2D 81
55  Chip geometry results fromThirdwave AdvantEdge 84
56  Cutting conditions for the chip geometry verification89
57  Experimentally measured cutting force results92
58  Predicted cutting force results fromMSCMarc92
59  Predicted cutting force results fromDEFORM2D93
510  Predicted cutting force results fromThirdwave AdvantEdge 94
511  Experimentally measured thrust force results 96
512  Predicted thrust force results estimated by MSCMarc97
513  Predicted thrust force results fromDEFORM2D98
514  Predicted thrust force resultsfromThirdwave AdvantEdge 99
515  Experimental and Simulation results of Movahhedy and Altintas 101
516  Comparison with literature (m=01)  101
517  Comparison with literature (m=07)  101
xii
LIST OF FIGURES
21  Orthogonal and Oblique Cutting 8
22  Chip samples produced by quick stop techniques9
23  Someof the variables in orthogonal cutting10
24  Assumed shape of deformation zone in cutting11
25  A photomicrograph of orthogonal cutting operation
where thin shear plane is approached12
26  An illustration of the mechanismofdiscontinuous chip formation 12
27  Idealized picture of built-up edge (BUE) formation13
28  Typical shape of the stress-strain relationship for
a metal under the action of a tensile stress 14
29  Shear zone types 16
210  Variables used in shear angle relationships17
211  Dependence of friction force to the normal force20
212  Frictional shear stress distribution on rake face of the tool21
213  Pre-Flow region22
214  Model by Strenkowski and Kyoung-Jin Moon25
215  Model by Stevenson, Wright and Chow27
216  Initial and deformed of the model by Arola and Ramulu30
217  Model developed Carroll and Strenkowski 31
218  Estimated chips at different rake angles by Carroll and Strenkowski32
219  The initial finite element mesh, configuration of the cutting
tool and dimensions of the elements developed by Shih34
xiii
220  Remeshing module used by Ceretti, Lucchi and Altan 35
221  Oxley’s theory and its simplified flow chart 36
222  Results of the work done by Borouchaki, Cherouat,
Laug and Saanouni 37
31  Schematic representation of orthogonal cutting and
velocity diagram 40
32  Orthogonal turning operation on a lathe41
33  Test Setup 42
34  Lathe tool dynamometer setup 43
35  Analog display of the dynamometer 44
36  Calibration of the dynamometer 45
37  Calibration curve for cutting force 45
38  Calibration curve for thrust force 46
39  Contact length on the rakeface of the tool 47
310  Microscope by which the thicknesses of chips were measured48
311  A sample microscope view while measuring thickness 48
312  Comparison of experimental and simulated
compressed specimens51
313  Comparison of punch displacement – punch force diagram 52
41  Finite element model of MSCMarc 54
42  Quadrilateral element 55
43  Distribution of generated heat due to friction57
44  Workpiece flow curve for strain-rate of 40 (s-1)58
45  Workpiece flow curve for strain-rate of 8 (s-1)59
46  Workpiece flow curve for strain-rate of 16 (s-1)59
47  Effect of strain-rate on the flow curves 60
48  Step function frictional stress and approximation by Equation 4561
xiv
49  Separation of chip fromthe workpiece by continuous remeshing 63
410  Finite element model of Deform2D 64
411  Element erase due to damage via remeshing in Deform2D 65
412  Finite element model of Third Wave Systems AdvantEdge 67
413  Six-noded triangular element69
51  A typical diagramof cutting force versus increment number 73
52  Effect of contact penetration value 74
53  Effect of penetration check method on the results74
54  Rake, Shear and Friction angle for an orthogonal cut 76
55  Allowable slip-line model solutions for rake angle of 20° 76
56  Allowable slip-line model solutions for rake angle of 25° 77
57  Shear angle can be found fromstrain-rate distribution 79
58  Effect of friction factor on the chip thickness results obtained
by MSCMarc 80
59  Effect of friction factor on the shear angles obtained by
MSCMarc calculated from chip thickness results 80
510  Effect of friction factor on the contact length results
by MSCMarc 81
511  Effect of friction factor on the chip thickness results
by Deform2D 82
512  Effect of friction factor on the shear angles obtained by
Deform2D calculated from chip thickness results83
513  Effect of friction factor on the contact length results by Deform2D83
514  Effect of friction factor on the chip thickness results by Thirdwave
AdvantEdge85
515  Effect of friction factor on the shear angles obtained by Thirdwave
AdvantEdge calculated fromchip thickness results 85
xv
516  Effect of friction factoron the contact length
by Thirdwave AdvantEdge86
517  Comparison of chip thickness results fromthree
codes with experiments87
518  Shear angles obtained by three codes fromchip thickness estimation88
519  Comparison of contact length results fromthree
codes with experiments90
520  Simulated chip geometries fromthree commercial
codes at 20° rake angle 91
521  Simulated chip geometries with three commercial
codes at 25° rake angle 93
522  Effect of Friction on the cutting force results of MSCMarc94
523  Effect of friction on the cutting force results of Deform2D 95
524  Effect of friction on the cutting force results of
Thirdwave AdvantEdge 95
525  Comparison of cutting forces estimated by
three codes and experiments96
526  Forces acting on the tool97
527  Effect of friction factor on the thrust force prediction of MSCMarc98
528  Effect of friction factor on the thrust force prediction
of Deform2D99
529  Effect of friction factoron the thrust force
by Thirdwave AdvantEdge100
530  Comparison of thrust forces estimated by three
codes and experiments102
531  Comparison of cutting and thrust forces obtained
by MSCMarc with experiment fromliterature 102
xvi
532  Comparison of shear angle obtained by MSCMarc
with experiment from literature 103
533  Comparison of contact length obtained by MSCMarc
with experiment from literature 103
534  Comparison of contact length estimated by MSCMarc
with experiment from literature
61  Crack generated by remeshing108


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