FINITE ELEMENT ANALYSIS OF CUTTING FORCES IN HIGH SPEED MACHINING

Jayghosh S. Rao Karthik Rai Shruthi N. Kumar Vishwajith V. Shetty Internal Guide:
Dr. H. D. Gopalakrishna Professor Dept. of Mechanical Engineering R. V. C. E.

- 1RV10ME034 - 1RV10ME037 - 1RV10ME098 - 1RV10ME119

Mini Project Leading to Major Project ( Yes / No )

Introduction
Metal cutting is one of the most used production processes in the industry, but it is the least examined. Experiments are capital intensive and time demanding. Since material database update at a very fast pace, the experimental results become obsolete. The development of a new machining process requires considerable investment of time and resources. Precise knowledge of the optimal range of cutting parameters is essential for timely startup. Process features such as tool geometry , cutting speed , feed rate and depth of cut directly influence chip morphology , cutting forces , product dimensionality , and tool life. Computer simulation of the cutting process can potentially reduce the number of design iterations and result in substantial cost savings.

Basic Principles & Current Applications

HSM involves a very high strain rate and deformation rate. Hence a Lagrangian formulation Mesh cannot by itself give accurate results due to element distortion. ALE on the other hand allows us to maintain decent aspect ratios even after deformation. This is because the mesh moves independently of the material and space. Cutting speeds are determined in a more or less empirical manner. We intend to chart the variation of cutting force with different parameters. Machining involves contact between the work piece and the tool hence resulting in mesh-on-mesh contact. Current applications mainly extend to industries where accurate and precise machining is crucial. FEM introduces a very resource-effective way to simulate the highly non-linear interaction between the tool and work piece. High speed machining is one of the important cutting processes used in the aerospace industry today.

Objectives
To develop a predictive model for the high speed orthogonal metal cutting process for Aluminium using FEM simulations. To study the metal cutting process at high speed and measure variation of cutting forces with speed and depth of cut.

Plan of Action

Literature Survey
Researchers have developed a large number of models to analyze and predict metal cutting behavior (empirical, analytical, finite element). The type of meshing in a Finite element analysis determines the practicality of the results (Lagrangian, Euler, SPH, ALE). Continuous re-meshing and adaptive meshing are tools to overcome deformation induced element distortion. FEA of machining is not fully capable of simulating 3-D machining operations due to computational requirements. Smooth Particle hydrodynamics is a realistic method and it also predicts the chip formation realistically.

Literature Gap
A review of literature reveals that most of the studies in HSM are experimental in nature. There is very little study of forces developed during Aluminium machining operation using HSS tool. 2D analysis of the said process has not been explored in detail. Since it has computational time advantage over 3D analysis cost competency will be a result of the study. Aluminium machining has been analyzed using the Lagrangian and SPH methodologies.

References
T.D.Marushich et al, Modelling and simulation of high speed machining ,(1995) Tugrul zel and Taylan Altan, Modeling of high speed machining process for predicting tool forces, stresses and temperatures using FEM simulations, (1998) Grama R Bhashyam , ANSYS Mechanical A Powerful Nonlinear simulation tool, (2002) J.Kanchana et al, Dynamics of High-speed Machining of Aerospace Structures using Finite-element Analysis,(2002) Morten F Villumsen et al, Prediction of cutting forces during metal cutting using FEA method , a Lagrangian approach , (2008) Morten F Villumsen et al, Simulation of Metal Cutting Using Smooth Particle Hydrodynamics,(2008) Jean Donea et al, Arbitrary Lagrangian Eulerian Methods