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Paper Information

Journal:   MODARES MECHANICAL ENGINEERING   MARCH 2017 , Volume 16 , Number 12 ; Page(s) 555 To 561.
 
Paper: 

3D FINITE ELEMENT SIMULATION OF MICRO-MILLING PROCESS OF TITANIUM ALLOY

 
 
Author(s):  REZAEI HAMED, SADEGHI MOHAMMAD HOSSEIN*
 
* DEPARTMENT OF MECHANICAL ENGINEERING, TARBIAT MODARES UNIVERSITY, TEHRAN, IRAN
 
Abstract: 

Nowadays, emergence of more advanced computer systems made it possible to simulate and model complex problems with even higher accuracy. Regarding lower time and cost, the use of simulations instead of physical experiments is increasingly considered as an alternative method in the analysis and optimization of process performance. The importance of such methods becomes more significant when talking about micro-processes, since there are lots of difficulties in experimental measurements as a result of scaling problems by scaling down from macro to micro. In this study, a 3D model is developed using Deform-3D software for prediction of micromilling process behavior. Effects of cutting parameters on such characteristics as cutting forces, temperature distribution and tool wear are investigated. Johnson-Cook model is used to define physical and mechanical properties of the material in simulation. Two types of sticking and sliding friction contacts were assigned along the toolworkpiece contact length to have more realistic cutting condition. The two types of sticking and sliding friction contacts were employed to have more realistic contact model. Usui wear model is used to predict tool wear rate in the simulation. To check the validity of the model, force results of simulation are compared with the measured ones. A high level of correlation exists between the obtained simulation and measured results, which shows that the 3D developed model has good capability to predict process behavior.

 
Keyword(s): MICROMILLING, CUTTING FORCE, TEMPERATURE, TOOL WEAR
 
References: 
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