3D FEA Simulations in Machining

3D FEA Simulations in Machining
Panagiotis Kyratsis , Anastasios Tzotzis , J. Paulo Davim
Contents
1 A Comparative Study Between 2D and 3D Finite Element
Methods in Machining . 1
1.1 Introduction 1
1.2 Comparison Between 2D and 3D FEM Analysis Techniques . 3
1.2.1 Evaluation of Cutting Forces and Torque . 3
1.2.2 Chip Formation and Dimensions Assessment . 4
1.2.3 Examination of Residual Stresses . 5
1.2.4 Temperature and Tool-Wear Assessment 6
1.3 Conclusions 8
References 10
2 Fundamentals of 3D Finite Element Modeling in Conventional
Machining 13
2.1 Introduction 13
2.1.1 FEM-Based Studies in Machining . 15
2.1.2 Advantages and Limitations of FEM . 17
2.2 Finite Element Modeling in Machining . 17
2.2.1 Meshing and Element Types 17
2.2.2 Mesh Adaptivity 21
2.2.3 Tool-Workpiece Representation . 23
2.2.4 Boundary Conditions 24
2.2.5 Material Flow Stress Modeling 27
2.2.6 Friction Modeling and Contact Description . 30
2.2.7 Material Separation . 34
2.2.8 Tool Wear 36
2.3 Typical FEM-Based Results . 37
2.3.1 Cuttings Forces, Torque, and Residual Stresses 37
2.3.2 Chip Morphology, Temperature Distribution, and Wear . 38
2.4 Conclusions and Perspectives . 39
References 39
vvi Contents
3 FEM-Based Study of AISI52100 Steel Machining: A Combined
2D and 3D Approach 47
3.1 Introduction 47
3.2 Materials and Methods . 49
3.2.1 Machining Process Framework 49
3.2.2 Preliminary FE Model Assessment 50
3.2.3 Numerical Modeling of the Turning Process in Three
Dimensions 54
3.3 Results and Findings . 56
3.3.1 Machining Forces Evaluation . 56
3.3.2 Chip Geometry Evaluation . 58
3.4 Conclusions 61
References 61
4 Experimental and 3D Numerical Study of AA7075-T6 Drilling
Process . 63
4.1 Introduction 63
4.2 Materials and Methods . 65
4.2.1 Layout of Experimental Testing . 65
4.2.2 Finite Element Layout . 66
4.3 Results and Findings . 70
4.3.1 Cutting Forces and Torque Analysis . 70
4.3.2 Chip Morphology Analysis . 71
4.3.3 Temperature Distribution Analysis . 72
4.3.4 Concluding Remarks 73
References 74
5 3D Finite Element Simulation of CK45 Steel Face-Milling: Chip
Morphology and Tool Wear Validation 77
5.1 Introduction 77
5.2 Materials and Methods . 79
5.2.1 Experimental Framework 79
5.2.2 Face-Milling CAD-Based Setup . 79
5.2.3 Numerical Modeling of the Face-Milling Process 81
5.3 Results and Discussion . 84
5.3.1 Chip Formation Analysis and Temperature Distribution
Evaluation . 84
5.3.2 Tool Wear Assessment . 85
5.4 Concluding Remarks . 87
References

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