In this study, a newly developed titanium superalloy, i.e., the Ti-5553 alloy has used for hot machining. This material replaced Ti-grade-5 alloy in the application of aerospace, automobile, and biomedical sector. How...In this study, a newly developed titanium superalloy, i.e., the Ti-5553 alloy has used for hot machining. This material replaced Ti-grade-5 alloy in the application of aerospace, automobile, and biomedical sector. However, similar to Ti-grade-5 alloy, the Ti-5553 alloy has a low thermal conductivity which makes it difficult-to-cut material categories hence, high tool wear, cutting force and bad surface finish. Hot machining of Ti-5553 has been studied at different machining condition (room and hot) using Deform-2D finite element analysis. The result from the simulation test was compared with the experimental value and reduction of cutting and thrust forces was observed. The experiment was carried out with the same input parameters as simulation, and good coherence between them observed. Additionally, cutting zone temperature, effective stress, etc. for both room and elevated the temperature are also discussed.展开更多
This study investigates the hot machining of Inconel 625 alloy by using flame heating under different machining conditions using finite element analysis(FEM).Turning tests are performed at different cutting speeds and...This study investigates the hot machining of Inconel 625 alloy by using flame heating under different machining conditions using finite element analysis(FEM).Turning tests are performed at different cutting speeds and heating temperatures using uncoated carbide insert by DEFORM software.Significant reduction in cutting force and tool wear has achieved at heating conditions compared to room temperature.Highest tool life is achieved at the highest cutting speed and higher heating temperature condition.At heating conditions of the 600℃ continuous chip is formed whereas at room temperature saw-tooth chip formation is observed.A significant agreement is achieved between simulated and experimental cutting forces and chip morphology.The effect of feed rates and depth of cuts are also studied experimentally during turning of Inconel 625 in a systematic manner.展开更多
This paper presents a modeling and simulation of micro-milling process with finite element modeling(FEM)analysis to predict cutting forces.The micro-milling of Inconel 718 is conducted using high-speed steel(HSS)micro...This paper presents a modeling and simulation of micro-milling process with finite element modeling(FEM)analysis to predict cutting forces.The micro-milling of Inconel 718 is conducted using high-speed steel(HSS)micro-end mill cutter of 1mm diameter.The machining parameters considered for simulation are feed rate,cutting speed and depth of cut which are varied at three levels.The FEM analysis of machining process is divided into three parts,i.e.,pre-processer,simulation and post-processor.In preprocessor,the input data are provided for simulation.The machining process is further simulated with the pre-processor data.For data extraction and viewing the simulated results,post-processor is used.A set of experiments are conducted for validation of simulated process.The simulated and experimental results are compared and the results are found to be having a good agreement.展开更多
In this paper,a two-dimensional axisymmetric thermal model using finite element method(FEM)has been established for predicting the temperature distribution pro-file on the work piece during electro discharge machining...In this paper,a two-dimensional axisymmetric thermal model using finite element method(FEM)has been established for predicting the temperature distribution pro-file on the work piece during electro discharge machining(EDM)and obtained material removal rate(MRR)from the temperature isotherm.For prediction of MRR,the model utilizes some important features viz.size and shape of the heat source(Gaussian heat distribution),thermal properties of workpiece,amount of heat distribution among the dielectric fluid,workpiece and tool,material flushing efficiency and pulse off/on time,etc.ANSYS software was used for developing the thermal model for the single spark operation.For this investigation,AISI 304 stainless steel and tungsten carbide was used as workpiece and electrode material,respectively.A comparison study has been carried out for theoretical and experimental MRR for the effect of each process parameter viz.gap voltage,pulse on time and peak current.The temperature distribution along the radial and depth direction of the workpiece has been reported.The model was validated by comparing the theoretical MRR with the experimental MRR and found a good correlation between them.展开更多
文摘In this study, a newly developed titanium superalloy, i.e., the Ti-5553 alloy has used for hot machining. This material replaced Ti-grade-5 alloy in the application of aerospace, automobile, and biomedical sector. However, similar to Ti-grade-5 alloy, the Ti-5553 alloy has a low thermal conductivity which makes it difficult-to-cut material categories hence, high tool wear, cutting force and bad surface finish. Hot machining of Ti-5553 has been studied at different machining condition (room and hot) using Deform-2D finite element analysis. The result from the simulation test was compared with the experimental value and reduction of cutting and thrust forces was observed. The experiment was carried out with the same input parameters as simulation, and good coherence between them observed. Additionally, cutting zone temperature, effective stress, etc. for both room and elevated the temperature are also discussed.
文摘This study investigates the hot machining of Inconel 625 alloy by using flame heating under different machining conditions using finite element analysis(FEM).Turning tests are performed at different cutting speeds and heating temperatures using uncoated carbide insert by DEFORM software.Significant reduction in cutting force and tool wear has achieved at heating conditions compared to room temperature.Highest tool life is achieved at the highest cutting speed and higher heating temperature condition.At heating conditions of the 600℃ continuous chip is formed whereas at room temperature saw-tooth chip formation is observed.A significant agreement is achieved between simulated and experimental cutting forces and chip morphology.The effect of feed rates and depth of cuts are also studied experimentally during turning of Inconel 625 in a systematic manner.
文摘This paper presents a modeling and simulation of micro-milling process with finite element modeling(FEM)analysis to predict cutting forces.The micro-milling of Inconel 718 is conducted using high-speed steel(HSS)micro-end mill cutter of 1mm diameter.The machining parameters considered for simulation are feed rate,cutting speed and depth of cut which are varied at three levels.The FEM analysis of machining process is divided into three parts,i.e.,pre-processer,simulation and post-processor.In preprocessor,the input data are provided for simulation.The machining process is further simulated with the pre-processor data.For data extraction and viewing the simulated results,post-processor is used.A set of experiments are conducted for validation of simulated process.The simulated and experimental results are compared and the results are found to be having a good agreement.
文摘In this paper,a two-dimensional axisymmetric thermal model using finite element method(FEM)has been established for predicting the temperature distribution pro-file on the work piece during electro discharge machining(EDM)and obtained material removal rate(MRR)from the temperature isotherm.For prediction of MRR,the model utilizes some important features viz.size and shape of the heat source(Gaussian heat distribution),thermal properties of workpiece,amount of heat distribution among the dielectric fluid,workpiece and tool,material flushing efficiency and pulse off/on time,etc.ANSYS software was used for developing the thermal model for the single spark operation.For this investigation,AISI 304 stainless steel and tungsten carbide was used as workpiece and electrode material,respectively.A comparison study has been carried out for theoretical and experimental MRR for the effect of each process parameter viz.gap voltage,pulse on time and peak current.The temperature distribution along the radial and depth direction of the workpiece has been reported.The model was validated by comparing the theoretical MRR with the experimental MRR and found a good correlation between them.
