Frontiers of Mechanical Engineering >
3D finite element prediction of chip flow, burr formation, and cutting forces in micro end-milling of aluminum 6061-T6
Received date: 09 Oct 2016
Accepted date: 29 Nov 2016
Published date: 19 Jun 2017
Copyright
Predictive models for machining operations have been significantly improved through numerous methods in recent decades. This study proposed a 3D finite element modeling (3D FEM) approach for the micro end-milling of Al6061-T6. Finite element (FE) simulations were performed under different cutting conditions to obtain realistic numerical predictions of chip flow, burr formation, and cutting forces. FE modeling displayed notable advantages, such as capability to easily handle any type of tool geometry and any side effect on chip formation, including thermal aspect and material property changes. The proposed 3D FE model considers the effects of mill helix angle and cutting edge radius on the chip. The prediction capability of the FE model was validated by comparing numerical model and experimental test results. Burr dimension trends were correlated with force profile shapes. However, the FE predictions overestimated the real force magnitude. This overestimation indicates that the model requires further development.
A. DAVOUDINEJAD , P. PARENTI , M. ANNONI . 3D finite element prediction of chip flow, burr formation, and cutting forces in micro end-milling of aluminum 6061-T6[J]. Frontiers of Mechanical Engineering, 2017 , 12(2) : 203 -214 . DOI: 10.1007/s11465-017-0421-6
1 |
Li H, Lai X, Li C,
|
2 |
Masuzawa T. State of the art of micromachining. CIRP Annals—Manufacturing Technology, 2000, 49(2): 473–488
|
3 |
Liu X, DeVor R E, Kapoor S G. An analytical model for the prediction of minimum chip thickness in micromachining. Journal of Manufacturing Science and Engineering, 2005, 128(2): 474–481
|
4 |
Bao W Y, Tansel I N. Modeling micro-end-milling operations. Part I: Analytical cutting force model. International Journal of Machine Tools and Manufacture, 2000, 40(15): 2155–2173
|
5 |
Arrazola P J, Özel T, Umbrello D,
|
6 |
Maurel-Pantel A, Fontaine M, Thibaud S,
|
7 |
Rubio L, De la Sen M, Longstaff A P,
|
8 |
Özel T, Altan T. Modeling of high speed machining processes for predicting tool forces, stresses and temperatures using FEM simulations. In: Proceedings of the CIRP International Workshop on Modeling of Machining Operations. Atlanta, 1998
|
9 |
Özel T, Altan T. Process simulation using finite element method prediction of cutting forces, tool stresses and temperatures in high-speed flat end milling. International Journal of Machine Tools and Manufacture, 2000, 40(5): 713–738
|
10 |
Liu K, Melkote S N. Finite element analysis of the influence of tool edge radius on size effect in orthogonal micro-cutting process. International Journal of Mechanical Sciences, 2007, 49(5): 650–660
|
11 |
Nasr M N A, Ng E G, Elbestawi M A. Modelling the effects of tool-edge radius on residual stresses when orthogonal cutting AISI 316L. International Journal of Machine Tools and Manufacture, 2007, 47(2): 401–411
|
12 |
Afazov S M, Ratchev S M, Segal J. Modelling and simulation of micro-milling cutting forces. Journal of Materials Processing Technology, 2010, 210(15): 2154–2162
|
13 |
Özel T, Liu X, Dhanorker A. Modelling and simulation of micro-milling process. In: Proceedings of the 4th International Conference and Exhibition on Design and Production of Machines and Dies/Molds. 2007
|
14 |
Jin X, Altintas Y. Prediction of micro-milling forces with finite element method. Journal of Materials Processing Technology, 2012, 212(3): 542–552
|
15 |
Thepsonthi T, Özel T. Experimental and finite element simulation based investigations on micro-milling Ti-6Al-4V titanium alloy: Effects of cBN coating on tool wear. Journal of Materials Processing Technology, 2013, 213(4): 532–542
|
16 |
Woon K S, Rahman M, Neo K S,
|
17 |
Wu H, Zhang S. 3D FEM simulation of milling process for titanium alloy Ti6Al4V. International Journal of Advanced Manufacturing Technology, 2014, 71(5–8): 1319–1326
|
18 |
Yang K, Liang Y, Zheng K,
|
19 |
Thepsonthi T, Özel T. 3-D finite element process simulation of micro-end milling Ti-6Al-4V titanium alloy: Experimental validations on chip flow and tool wear. Journal of Materials Processing Technology, 2015, 221: 128–145
|
20 |
Chen, M, Ni H, Wang Z,
|
21 |
Advantedge T W.User manual for Third Wave AdvantEdge Version 6.2.011, USA
|
22 |
Man X, Ren D, Usui S,
|
23 |
Davoudinejad A, Chiappini E, Tirelli S,
|
24 |
Arrazola P J, Özel T. Investigations on the effects of friction modeling in finite element simulation of machining. International Journal of Mechanical Sciences, 2010, 52(1): 31–42
|
25 |
Özel T. The influence of friction models on finite element simulations of machining. International Journal of Machine Tools and Manufacture, 2006, 46(5): 518–530
|
26 |
Kim K W, Lee W Y, Sin H C. A finite element analysis for the characteristics of temperature and stress in micro-machining considering the size effect. International Journal of Machine Tools and Manufacture, 1999, 39(9): 1507–1524
|
27 |
Al-Qutub A M, Khalil A, Saheb N,
|
28 |
Bathurst S P, Kim S G. Designing direct printing process for improved piezoelectric micro-devices. CIRP Annals—Manufacturing Technology, 2009, 58(1): 193–196
|
29 |
Annoni M, Pusterla N, Rebaioli L,
|
30 |
Hashimura M, Hassamontr J, Dornfeld D A. Effect of in-plane exit angle and rake angles on burr height and thickness in face milling operation. Journal of Manufacturing Science and Engineering, 1999, 121(1): 13–19
|
31 |
Davoudinejad A. 3D finite element modeling of micro end-milling by considering tool run-out, temperature distribution, chip and burr formation. Dissertation for the Doctoral Degree. Milan: Polytechnic University of Milan, 2016
|
32 |
JohnsonG R, Cook W H. A constitutive model and data for metals subjected to large strains, high strain rates and high temperatures. In: Proceedings of the 7th International Symposium on Ballistics. The Hague, 1983, 541–547
|
33 |
Calamaz M, Coupard D, Girot F. A new material model for 2D numerical simulation of serrated chip formation when machining titanium alloy Ti-6Al-4V. International Journal of Machine Tools and Manufacture, 2008, 48(3–4): 275–288
|
/
〈 |
|
〉 |