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 Background Information on Single-Point Turning Elements of Single Point Turning Elements of Single Point Turning Material Cases: Material Cases:  Grade 410 Stainless Steel (Annealed)  Brass Material (As-Sintered)  Aluminum Alloy Al2024-T3511 (Cold-Drawn)  Inconel 718 FEM Model setup FEM Model setup Depth of Cut Depth of Cut Feed Feed Speed Speed Rake Angle Rake Angle Tool Material Tool Material FEM Results FEM Results Theories & Calculations Theories & Calculations Conclusion Conclusion

Elements of Single Point Turning (Orthogonal) Machining angles: Machining angles:  Rake angle, α  Friction Angle, λ  Shear Plane Angle, φ

Material Cases AISI Grade 4130 Alloy (Medium Carbon) AISI Grade 4130 Alloy (Medium Carbon) Hardness = 375 Bhn Hardness = 375 Bhn Yield Strength = 883 MPa Yield Strength = 883 MPa

Material Cases Type C37700 Brass Material Type C37700 Brass Material Hardness = 81 Bhn Hardness = 81 Bhn Yield Strength = 138 MPa Yield Strength = 138 MPa

Material Cases Al 2024-T3511 Hardness = 38 to 50 Bhn Hardness = 38 to 50 Bhn Yield Strength = 170MPa Yield Strength = 170MPa

Material Cases Iconel 718 Hardness = 454 Bhn Hardness = 454 Bhn Yield Strength = 1103MPa Yield Strength = 1103MPa

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

FEM Results AISI Grade 4130 Alloy (Medium Carbon) AISI Grade 4130 Alloy (Medium Carbon) Rake Angle 0 0 Max Shear Stress MPa AISI Grade 4130 Alloy (Medium Carbon) AISI Grade 4130 Alloy (Medium Carbon) Rake Angle 45 0 Max Shear Stress MPa

FEM Results AISI Grade 4130 Alloy (Medium Carbon) Rake Angle 0 0 Cutting & Thrust Forces AISI Grade 4130 Alloy (Medium Carbon) AISI Grade 4130 Alloy (Medium Carbon) Rake Angle 45 0 Cutting & Thrust Forces

FEM Results AISI Grade 4130 Alloy (Medium Carbon) AISI Grade 4130 Alloy (Medium Carbon) Rake Angle 0 0 Max Von Mises Stress MPa AISI Grade 4130 Alloy (Medium Carbon) AISI Grade 4130 Alloy (Medium Carbon) Rake Angle 45 0 Max Von Mises Stress MPa

FEM Results AISI Grade 4130 Alloy (Medium Carbon) AISI Grade 4130 Alloy (Medium Carbon) Rake Angle 0 0 Max Temperature AISI Grade 4130 Alloy (Medium Carbon) AISI Grade 4130 Alloy (Medium Carbon) Rake Angle 45 0 Max Temperature

FEM Results AISI Grade 4130 Alloy (Medium Carbon) AISI Grade 4130 Alloy (Medium Carbon) Rake Angle 0 0 Max Pressure AISI Grade 4130 Alloy (Medium Carbon) AISI Grade 4130 Alloy (Medium Carbon) Brass Rake Angle 45 0 Max Pressure

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

FEM Results Type C37700 Brass Rake Angle 0 0 Max Shear Stress MPa Type C37700 Brass Rake Angle 45 0 Max Shear Stress

FEM Results Type C37700 Brass Rake Angle 0 0 Cutting & Thrust Forces Type C37700 Brass Rake Angle 45 0 Cutting & Thrust Forces

FEM Results Type C37700 Brass Rake Angle 0 0 Max Von Mises Stress MPa Type C37700 Brass Rake Angle 45 0 Max Von Mises Stress

FEM Results Type C37700 Brass Rake Angle 0 0 Max Temperature Type C37700 Brass Rake Angle 45 0 Max Temperature

FEM Results Type C37700 Brass Rake Angle 0 0 Plastic Strain Type C37700 Brass Rake Angle 45 0 Plastic Strain

FEM Results Type C37700 Brass Rake Angle 0 0 Max Pressure Type C37700 Brass Rake Angle 45 0 Max Pressure

FEM Results Al 2024-T3511 (Cold Drawn) Al 2024-T3511 (Cold Drawn) Input Parameters: Input Parameters: Depth of Cut = 4 mm Depth of Cut = 4 mm Feed = 0.4 mm/rev Feed = 0.4 mm/rev Speed = 275 m/min Speed = 275 m/min Rake Angle = 0 ° Rake Angle = 0 ° Cutting Radius = 0.02 mm Cutting Radius = 0.02 mm Relief Angle = 10 ° Relief Angle = 10 ° Cutting Tool – HSS-General Cutting Tool – HSS-General Click on the image to animate the results

FEM Results Al 2024-T3511 Rake Angle 15 0 Max Temp 334 Deg C Al 2024-T3511 Rake Angle Max Temp 350 Deg C

FEM Results Al 2024-T3511 Rake Angle 15 0 Plastic Strain Al 2024-T3511 Rake Angle Plastic Strain

FEM Results Al 2024-T3511 Rake Angle 15 0 Cutting & Thrust Force Al 2024-T3511 Rake Angle Cutting & Thrust Force

FEM Results Al 2024-T3511 Rake Angle 15 0 Max Von Mises Stress 3573 MPa Al 2024-T3511 Rake Angle Max Von Mises Stress 2950 MPa

FEM Results Al 2024-T3511 Rake Angle 15 0 Max Shear Stress 1887 MPa Al 2024-T3511 Rake Angle Max Shear Stress 1589 MPa

FEM Results Al 2024-T3511 Rake Angle 15 0 Max Pressure 3120 MPa Al 2024-T3511 Rake Angle Max Pressure 2261 MPa

FEM Results Inconel 718 Inconel 718 Input Parameters: Input Parameters: Depth of Cut = 4 mm Depth of Cut = 4 mm Feed = 0.25 mm/rev Feed = 0.25 mm/rev Speed = 23 m/min Speed = 23 m/min Rake Angle = 0 ° Rake Angle = 0 ° Cutting Radius = 0.02 mm Cutting Radius = 0.02 mm Relief Angle = 10 ° Relief Angle = 10 ° Cutting Tool – HSS-General Cutting Tool – HSS-General Click on the image to animate the results

FEM Results Inconel 718 Rake Angle 15 0 Max Temp 820 Deg C Inconel 718 Rake Angle Max Temp 814 Deg C

FEM Results Inconel 718 Rake Angle 15 0 Plastic Strain Inconel 718 Rake Angle Plastic Strain

FEM Results Inconel 718 Rake Angle 15 0 Cutting & Thrust Force Inconel 718 Rake Angle Cutting & Thrust Force

FEM Results Inconel 718 Rake Angle 15 0 Max Von Mises Stress MPa Inconel 718 Rake Angle Max Von Mises Stress 6852 MPa

FEM Results Inconel 718 Rake Angle 15 0 Max Shear Stress 7305 MPa Inconel 718 Rake Angle Max Shear Stress 2845 MPa

FEM Results Inconel 718 Rake Angle 15 0 Max Pressure MPa Inconel Rake Angle Max Pressure MPa

FEM Results Inconel 718 Inconel 718 Input Parameters: Input Parameters: Depth of Cut = 4 mm Depth of Cut = 4 mm Feed = 0.25 mm/rev Feed = 0.25 mm/rev Speed = 23 m/min Speed = 23 m/min Rake Angle = 0 ° Rake Angle = 0 ° Cutting Radius = 0.02 mm Cutting Radius = 0.02 mm Relief Angle = 10 ° Relief Angle = 10 ° Cutting Tool – HSS-General Cutting Tool – HSS-General Cutting Tool – Carbide General Cutting Tool – Carbide General HSS Carbide

Theories & Calculations  Friction Angle Calculation: Al 2024-T3511 Rake Angle 0 0 tan -1 (0.25)=14 λ = 14 0 λ = 14 0

Theories & Calculations

Theories & Calculations (Cont.)

Conclusion

References Metal Machining - Theory and Applications By: Childs, T.H.C.; Maekawa, K.; Obikawa, T.; Yamane, Y. © 2000 Elsevier Metal Machining - Theory and Applications By: 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 M.C. Shaw, Metal Cutting Principles, 2nd ed., Oxford U.P., New York, 2005 Third Wave AdvantEdge User Manual Third Wave AdvantEdge User Manual