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8/18/2019 science book

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PRESENTATION ON PROJECT TITLED

FEM study on the efect o the tool geometry on the machining aspects(Turning) o steel alloy

Under the supervision of, presented by,Dr.G.S!"!#$S%, D.$$#!"D EDD&'*+$ssistant proessor, D%--$ D!"ES'*+/Mechanical Engineering, ".#.0$!T$"&$ M$"1$'*+/2 3.M$"14 -%M$ EDD&'*+52


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!"T1D%0T!1"


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TE TURNIN! PROCESS∗ Turning is a very important machining process in which a single-

point cutting tool removes material from the surface of a rotating

cylindrical work piece.

∗ The cutting tool is feed linearly in a direction parallel to the axis ofrotation.

∗ Therefore, Five cutting parameters, i.e. cutting speed, feed rate, and

depth of cut, tool geometry (nose radius) and cutting conditionexist.

∗ The free body diagram of the turning process with different forces

is below, called erchant!s force diagram.


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"i#ure$% "i#ure$&

'Turnin# pro(ess) '*er(h+nt (ir(edi+#r+-)


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Finite Element Analysis of Turning Process

∗ Finite element analysis is a most useful and accurate approachfor the determination of field variables that is made possible by

advancements in computational and processing power of

computers

∗ "n this method of analysis, a complex region defining a

continuum is discredited into simple geometric shapes called

finite elements.

∗ The #resent work is also based on the application of finite

element for analysis of different parameters while using single

point cutting tool for turning operation.


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∗ odelling $% cutting process using finite element techni&ues is

an area of on going research activity due to significant costsavings and offers insights into the process which are not easily

measured in experiments.

ABOUT DEFORM 3D

∗ %'F is a Finite 'lement ethod (F') based process

simulation system designed to analyse various forming and heat

treatment processes used by metal forming and related industries.

∗ *nlike general purpose F' codes, %'F is tailored for

deformation modelling.


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∗+utting forces, cutting temperatures, chip shape, tool wear andtool life computations can be performed using this system.

∗ The insert geometry can be made available in T form,

generated from any +% system.


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6!TE$T%E E#!E7


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∗ "n a study by Tu#/ru O0 1e , T+y+n At+n2%3, theydeter-ined 4or5 pie(e 6o4 stress +nd fri(tion +tthe (hip7too (ont+(t for hi#h$speed (uttin# byusin# +n+yti(+ -ethods +nd (o-p+red the-4ith the e8peri-ent+ or -e+sured v+ues.

∗ They also used %'F /% in the process to initially

compare the estimated force values with the values obtained by

performing simulations using %'F /% .

∗ The results obtained are satisfactory , but they can not improve

the conditions for optimum cutting.

∗ The graphs obtained by them are shown below


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The graphs obtained by them are shown below0


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∗ "n another study by D. Ulutan, I. Lazoglu and C. Dinc ,[2]they predicted three-dimensional temperature in machining

processes using finite difference method.

∗ They used many formulae to determine the convective andconduction coefficients for the heat transfer between the chip

and tool.


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∗

They used expensive experimental setup comprising of"1F'% e&uipment to determine experimental temperature

condition at the interface.


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∗

The results obtained by analytical methods are compared withthe ones obtained by experimental methods .s far the below

graphs are considered, the values are agreeable.


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∗

"n another study by Tugrul 2 3el ,4$5 the influence of frictionmodels on finite element simulations of machining is studied.

∗ lmost same as the above cases, they also used analytical

formulae to calculate the force and the stress rates.

∗ Those values are then compared with the values those obtained

with F' simulations.

∗ 6ariable friction model is used to predict the values throought

the study.


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ome of the results obtained by them are below 0-


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3186EM!DE"T!F!0$T!1"


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∗ ince the metal turning operations have a very complex

structure, it is &uite difficult to solve them analytically.

∗ 'xperimental method is both costly and time-consuming.

7owever, this complex structure can be solved easily by using

numeric analyses based on finite element method (F').

∗ odelling metal turning processes in three dimensional ($%)

by using F' may be useful for validation of experimental

studies and it can be also considered as a reliable tool for new

metal removal techni&ues.


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∗ The #8' of suboptimum conditions which lead to

decrease in efficiency of the machining operation can be solved

by considering above methods.

∗ nother #8' for machining is the cost of machining for

costly materials and for which machining cost is very high .For

example Titanium is difficult to machine .8ut this can be easily

done by using software.

∗ 8y using this method, improvements in the output conditions

can also be made by changing input variables and conditions.


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∗ 6arious simulations can be done for each experiment and

optimum condition at which minimum tool wear and minimum

temperature occurs can be found.

∗ 8y changing the tool definition temperature at the tool work

piece interface can be reduced.

∗ 7ere if a tool with small grooves cut on it is used, it would be

able to cut the work piece effectively. The grooves can be made

by using diamond cutting tool.


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∗ s diamond cutting of a tool would be costly and that toomaking micro grooves within ultra-precision is even more

costly, we can simply use the software simulation by designing

the tool in the $d drawing methods .

∗ The re&uired T file can be made by using *T+%.


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*ETODOLO!9


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STARTIN! :IT ;D *ACININ!


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PROCESS SETUP ANDCONDITIONS


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INSERT TOOL DE"INITION


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TOOL OLDER DE"INITION


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TOOL *ES !ENERATION


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:OR< PIECE !EO*ETR9


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LOAD :OR< PIECE

*ATERIAL


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SI*ULATION CONTROLE AND TOOL :EAR DE"INITION


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RUNNIN! TE SI*ULATION


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E93E0TED1%T01ME


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Deveop-ent of "E* -ode to study the e=e(t of

too -odi>(+tion on ? Interf+(e te-per+ture*+teri+ re-ov+ r+te Too 4e+r

Cuttin# for(es


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EFEE"0ES


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∗ 2%3 J..L.


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∗ 23 E. De#/ir-en(i, *. sn Diri5ou, A ther-o(he-i(++ppro+(h for the deter-in+tion of (onve(tion he+t tr+nsfer(oe@(ients in + #un b+rre, App. Ther-. En#. ;B '&%&) &BK7&B.

∗ 2B3 E. Ceretti, L. "ii(e, D. U-breo, ". *i(+ri, ALE si-u+tion of

ortho#on+ (uttin#? + ne4 +ppro+(h to -ode he+t tr+nsferpheno-en+ +t the too7(hip interf+(e, CIRP Ann+s 7 *+nuf.

Te(hno. K '&B) 7B&.

∗ 2F3 D. Uut+n, I. L+1o#u, C. Din(, Three$di-ension+ te-per+turepredi(tions in -+(hinin# pro(esses usin# >nite di=eren(e-ethod, J. *+ter. Pro(ess. Te(hno. & '&) %%%%7%%&%.

∗ 23 S.


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∗ 2%%3 A.E. G+you-i, !. 9(es+n, D.M. utton, On the (osed for--e(h+nisti( -odein# of -iin#? spe(i>( (uttin# ener#y, torue,+nd po4er, J*EP ; '%) %K%7%KF.

∗ 2%&3 T. 1e, T. At+n, Deter-in+tion of 4or5 pie(e 6o4 stress +ndfri(tion +t the (hip7too (ont+(t for hi#h$speed (uttin#, Int. J. *+(h.

Toos *+nuf. '&) %;;7%K&. ∗

2%;3 T. 1e, The in6uen(e of fri(tion -odes on >nite ee-entsi-u+tions of -+(hinin#, Int. J. *+(h. Toos *+nuf. '&) K%F7K;.

∗ 2%3 T. 1e, E. Heren, A -ethodoo#y to deter-ine 4or5 -+teri+

6o4 stress +nd too7(hip interf+(i+ fri(tion properties by usin#

+n+ysis of -+(hinin#, J. *+nuf. S(i. En#. %&F '&K) %%7%&. ∗ 2%K3 DE"OR*$;D *+teri+ Libr+ry.

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