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Single Point Turning of Materials Using FEM Simulations . Presented by: Chris Wells Brant Liou. Single Point Turning of Materials Using FEM Simulations. Background Information on Single-Point Turning Elements of Single Point Turning Material Cases: Grade 410 Stainless Steel (Annealed)

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Single Point Turning of Materials Using FEM Simulations

  • Background Information on Single-Point Turning

  • Elements of Single Point Turning

  • Material Cases:

    • Grade 410 Stainless Steel (Annealed)

    • Brass Material (As-Sintered)

    • Aluminum Alloy Al2024-T3511 (Cold-Drawn)

    • Inconel 718

  • FEM Model setup

    • Depth of Cut

    • Feed

    • Speed

    • Rake Angle

    • Tool Material

  • FEM Results

  • Theories & Calculations

  • Conclusion


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Elements of Single Point Turning (Orthogonal)

  • Machining angles:

    • Rake angle, α

    • Friction Angle, λ

    • Shear Plane Angle, φ


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Material Cases

  • AISI Grade 4130 Alloy (Medium Carbon)

  • Hardness = 375 Bhn

  • Yield Strength = 883 MPa


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Material Cases

  • Type C37700 Brass Material

  • Hardness = 81 Bhn

  • Yield Strength = 138 MPa


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Material Cases

  • Al 2024-T3511

  • Hardness = 38 to 50 Bhn

  • Yield Strength = 170MPa


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Material Cases

  • Iconel 718

  • Hardness = 454 Bhn

  • Yield Strength = 1103MPa


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FEM Results

  • AISI Grade 4130 Alloy (Medium Carbon)

  • Input Parameters:

    • Depth of Cut = 4 mm

    • Feed = 0.4 mm/rev

    • Speed = 100 m/min

    • Rake Angle = 0°

    • Cutting Radius = 0.02 mm

    • Relief Angle = 10°

    • Cutting Tool – HSS-General

Click on the image to animate the results


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FEM Results

AISI Grade 4130 Alloy (Medium Carbon)Rake Angle 00

Max Shear Stress 4623.12 MPa

AISI Grade 4130 Alloy (Medium Carbon)Rake Angle 450

Max Shear Stress 5996.24 MPa


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FEM Results

AISI Grade 4130 Alloy (Medium Carbon)

Rake Angle 00

Cutting & Thrust Forces

AISI Grade 4130 Alloy (Medium Carbon)Rake Angle 450

Cutting & Thrust Forces


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FEM Results

AISI Grade 4130 Alloy (Medium Carbon)Rake Angle 00

Max Von Mises Stress 8060.08 MPa

AISI Grade 4130 Alloy (Medium Carbon)Rake Angle 450

Max Von Mises Stress 12725.1 MPa


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FEM Results

AISI Grade 4130 Alloy (Medium Carbon)Rake Angle 00

Max Temperature 603.08

AISI Grade 4130 Alloy (Medium Carbon)Rake Angle 450

Max Temperature 516.749


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FEM Results

AISI Grade 4130 Alloy (Medium Carbon)Rake Angle 00

Max Pressure 5315.14

AISI Grade 4130 Alloy (Medium Carbon)Brass Rake Angle 450

Max Pressure 15906.1


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FEM Results

  • Type C37700 Brass

  • Input Parameters:

    • Depth of Cut = 4 mm

    • Feed = 0.4 mm/rev

    • Speed = 100 m/min

    • Rake Angle = 0°

    • Cutting Radius = 0.02 mm

    • Relief Angle = 10°

    • Cutting Tool – HSS-General

Click on the image to animate the results


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FEM Results

Type C37700 Brass Rake Angle 00

Max Shear Stress 2044.74 MPa

Type C37700 Brass Rake Angle 450

Max Shear Stress 1598.75


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FEM Results

Type C37700 Brass Rake Angle 00

Cutting & Thrust Forces

Type C37700 Brass Rake Angle 450

Cutting & Thrust Forces


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FEM Results

Type C37700 Brass Rake Angle 00

Max Von Mises Stress 3928.02 MPa

Type C37700 Brass Rake Angle 450

Max Von Mises Stress 2896.23


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FEM Results

Type C37700 Brass Rake Angle 00

Max Temperature 358.41

Type C37700 Brass Rake Angle 450

Max Temperature 305.29


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FEM Results

Type C37700 Brass Rake Angle 00

Plastic Strain

Type C37700 Brass Rake Angle 450

Plastic Strain


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FEM Results

Type C37700 Brass Rake Angle 00

Max Pressure 3668.05

Type C37700 Brass Rake Angle 450

Max Pressure 1797.33


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FEM Results

  • Al 2024-T3511 (Cold Drawn)

  • Input Parameters:

    • Depth of Cut = 4 mm

    • Feed = 0.4 mm/rev

    • Speed = 275 m/min

    • Rake Angle = 0°

    • Cutting Radius = 0.02 mm

    • Relief Angle = 10°

    • Cutting Tool – HSS-General

Click on the image to animate the results


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FEM Results

Al 2024-T3511 Rake Angle 150

Max Temp 334 Deg C

Al 2024-T3511 Rake Angle -150

Max Temp 350 Deg C


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FEM Results

Al 2024-T3511 Rake Angle 150

Plastic Strain

Al 2024-T3511 Rake Angle -150

Plastic Strain


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FEM Results

Al 2024-T3511 Rake Angle -150

Cutting & Thrust Force

Al 2024-T3511 Rake Angle 150

Cutting & Thrust Force


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FEM Results

Al 2024-T3511 Rake Angle 150

Max Von Mises Stress 3573 MPa

Al 2024-T3511 Rake Angle -150

Max Von Mises Stress 2950 MPa


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FEM Results

Al 2024-T3511 Rake Angle 150

Max Shear Stress 1887 MPa

Al 2024-T3511 Rake Angle -150

Max Shear Stress 1589 MPa


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FEM Results

Al 2024-T3511 Rake Angle 150

Max Pressure 3120 MPa

Al 2024-T3511 Rake Angle -150

Max Pressure 2261 MPa


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FEM Results

  • Inconel 718

  • Input Parameters:

    • Depth of Cut = 4 mm

    • Feed = 0.25 mm/rev

    • Speed = 23 m/min

    • Rake Angle = 0°

    • Cutting Radius = 0.02 mm

    • Relief Angle = 10°

    • Cutting Tool – HSS-General

Click on the image to animate the results


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FEM Results

Inconel 718 Rake Angle -150

Max Temp 814 Deg C

Inconel 718 Rake Angle 150

Max Temp 820 Deg C


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FEM Results

Inconel 718 Rake Angle 150

Plastic Strain

Inconel 718 Rake Angle -150

Plastic Strain


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FEM Results

Inconel 718 Rake Angle -150

Cutting & Thrust Force

Inconel 718 Rake Angle 150

Cutting & Thrust Force


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FEM Results

Inconel 718 Rake Angle 150

Max Von Mises Stress 14526 MPa

Inconel 718 Rake Angle -150

Max Von Mises Stress 6852 MPa


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FEM Results

Inconel 718 Rake Angle 150

Max Shear Stress 7305 MPa

Inconel 718 Rake Angle -150

Max Shear Stress 2845 MPa


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FEM Results

Inconel 718 Rake Angle 150

Max Pressure 15427 MPa

Inconel Rake Angle -150

Max Pressure 11186 MPa


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FEM Results

HSS

HSS

  • Inconel 718

  • Input Parameters:

    • Depth of Cut = 4 mm

    • Feed = 0.25 mm/rev

    • Speed = 23 m/min

    • Rake Angle = 0°

    • Cutting Radius = 0.02 mm

    • Relief Angle = 10°

    • Cutting Tool – HSS-General

    • Cutting Tool – Carbide General

Carbide

Carbide


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Theories & Calculations

  • Friction Angle Calculation:

  • Al 2024-T3511 Rake Angle 00

  • tan -1(0.25)=14

  • λ = 140





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References

  • Metal Machining - Theory and ApplicationsBy: Childs, T.H.C.; Maekawa, K.; Obikawa, T.; Yamane, Y.   © 2000 Elsevier

  • M.C. Shaw, Metal Cutting Principles, 2nd ed., Oxford U.P., New York, 2005

  • Third Wave AdvantEdge User Manual


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