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Optimizing High Speed End Milling Of Titanium Alloy Using Mechanistic Model Fea And Experimental Design Techniques
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Book Synopsis Optimizing High Speed End-milling of Titanium Alloy Using Mechanistic Model, FEA and Experimental Design Techniques by : Sandeep Reddy Aramalla
Download or read book Optimizing High Speed End-milling of Titanium Alloy Using Mechanistic Model, FEA and Experimental Design Techniques written by Sandeep Reddy Aramalla and published by . This book was released on 2006 with total page 280 pages. Available in PDF, EPUB and Kindle. Book excerpt: "This thesis presents the results of modeling cutting forces, residual stresses and peak tool temperature in High speed end-milling of titanium (Ti-6Al-4V) alloys. Three different approaches namely: Finite element analysis, mechanistic model and experimental verification were used for the modeling and simulating cutting forces"--Abstract, leaf iv.
Book Synopsis 3D FEA Simulations in Machining by : Panagiotis Kyratsis
Download or read book 3D FEA Simulations in Machining written by Panagiotis Kyratsis and published by Springer Nature. This book was released on 2023-03-14 with total page 95 pages. Available in PDF, EPUB and Kindle. Book excerpt: This book covers machining simulations using advanced nonlinear finite element analysis (FEA) methodologies coupled with CAD-based techniques. The content increases awareness about the possibilities to reduce the actual experimental work via experimentally validated simulations using nonlinear finite element analysis.
Book Synopsis Machining of Titanium Alloys by : J. Paulo Davim
Download or read book Machining of Titanium Alloys written by J. Paulo Davim and published by Springer. This book was released on 2014-07-05 with total page 154 pages. Available in PDF, EPUB and Kindle. Book excerpt: This book presents a collection of examples illustrating the resent research advances in the machining of titanium alloys. These materials have excellent strength and fracture toughness as well as low density and good corrosion resistance; however, machinability is still poor due to their low thermal conductivity and high chemical reactivity with cutting tool materials. This book presents solutions to enhance machinability in titanium-based alloys and serves as a useful reference to professionals and researchers in aerospace, automotive and biomedical fields.
Book Synopsis Development of Virtual CNC Machine Tools and Web-based Machining Process Simulation: Mechanistic Cutting Force Models and Determination of Specific Force Coefficients in Helical End Milling by : Vinay Rao Talekar
Download or read book Development of Virtual CNC Machine Tools and Web-based Machining Process Simulation: Mechanistic Cutting Force Models and Determination of Specific Force Coefficients in Helical End Milling written by Vinay Rao Talekar and published by . This book was released on 2011 with total page 304 pages. Available in PDF, EPUB and Kindle. Book excerpt: "This thesis presents the results of the investigations of mechanistic modeling and simulation of cutting forces in high speed end milling of titanium alloy, Ti-6Al-4V, and the determination of specific cutting and edge force coefficients for carbide bull-nose helical end-mill. A generalized mathematical model representing the outer geometry of an end-mill and the cutter edge geometry is presented. Mechanistic cutting force models have been developed for a general helical end-mill and modeled specifically for a bullnose helical end-mill. A MATLAB code for the mechanistic cutting force models have been developed for the simulation of cutting force components in end milling and for the determination of specific cutting and edge force coefficients for any workpiece-tool material pair. Specific cutting and edge force coefficients are obtained for carbide bullnose helical end-mill - titanium alloy workpiece material pair at 10% radial immersion up-milling experiments. The effects of machining parameters: feed per tooth, helix angle, axial depth of cut, corner radius, number of cutter flutes, and spindle speed on cutting forces were investigated. End milling experiments were conducted on titanium alloy, Ti-6Al-4V, using a 0.5 inch (12.7 mm) diameter carbide bull-nose helical end-mill to verify the models. Predicted cutting force components (F[subscript x], F[subscript y], and F[subscript z]) obtained by the mechanistic cutting force models were compared with measured experimental values, and also with predicted and measured values from published literature. The results were in good agreement in both cases. This method for the determination of specific force coefficients and predicting cutting forces for titanium alloys can easily be extended to other metal alloys such as Hastelloy, Inconel, and niobium alloys"--Abstract, leaf iv.
Book Synopsis Modern Optimization Techniques for Advanced Machining by : Imhade P. Okokpujie
Download or read book Modern Optimization Techniques for Advanced Machining written by Imhade P. Okokpujie and published by Springer Nature. This book was released on 2023-07-21 with total page 364 pages. Available in PDF, EPUB and Kindle. Book excerpt: Advanced manufacturing via computer numerical machining is the art of producing mechanical components employed in aerospace, automobile, and industrial applications where a high level of accuracy is needed. This book focuses on the nano-machining of aluminum alloy and its optimization. The application of aluminum alloy in the manufacturing industry has increased tremendously due to its lightweight to high strength ratio and high-level resistance to corrosion. However, aluminum alloy has some challenges during the machining and manufacturing stage in order to solve real-life manufacturing challenges in advanced machining operation for sustainable production processes. Therefore, it is a need for the implementation of a general algebraic modeling system (GAMS) and other metaheuristic techniques for problem solving and to effectively develop mathematical models for high accuracy prediction and optimization under nano-lubrication machining conditions. This book discusses majorly on the major three responses in machining such as surface roughness, cutting force, and material removal rate, which will give an excellent guide to undergraduate and postgraduate students, senior research fellows in academia, operational, and strategic staff in manufacturing industries.
Book Synopsis High Speed Machining of Titanium Alloy, Ti6Al4V by : A. K. M. Nurul Amin
Download or read book High Speed Machining of Titanium Alloy, Ti6Al4V written by A. K. M. Nurul Amin and published by LAP Lambert Academic Publishing. This book was released on 2012 with total page 128 pages. Available in PDF, EPUB and Kindle. Book excerpt: High speed end milling of Titanium alloy Ti6Al4V is a potential machining technique for obtaining nano level surface finish using small diameter (2mm and 4mm) tools applying high rpm to facilitate the application of of low values (micro-meter level) of feeda and depth of cut to ensure super finishing that could avoid the need of further grinding and polishing operations. Influences of three cutting parameters, namely cutting speed, axial depth of cut and feed, were analyzed. Mathematical models were developed for output responses Ra and Rt. Analysis of multiple response optimizations of RSM and GA were done to get the best achievable response values. Maximum desirability of 98% was obtained with Ra value of 0.13m and Rt value of 3.72m.
Book Synopsis A STUDY OF HIGH-SPEED MILLING by : L. V. Colwell, L. J. Quackenbush
Download or read book A STUDY OF HIGH-SPEED MILLING written by L. V. Colwell, L. J. Quackenbush and published by . This book was released on 1962 with total page 84 pages. Available in PDF, EPUB and Kindle. Book excerpt:
Book Synopsis Finite Element Analysis and Design Optimization of Deep Cold Rolling of Titanium Alloy at Room and Elevated Temperatures by : Armin Hadadian
Download or read book Finite Element Analysis and Design Optimization of Deep Cold Rolling of Titanium Alloy at Room and Elevated Temperatures written by Armin Hadadian and published by . This book was released on 2020 with total page 0 pages. Available in PDF, EPUB and Kindle. Book excerpt: High strength-to-density ratio, high corrosion resistance and superior biocompatibility are the main advantages of Ti-6Al-4V (Ti64), making it a long been favored titanium alloy for aerospace and biomedical applications. Designing titanium components to last longer and refurbishing of aged ones using surface treatments have become a desirable endeavor considering high environmental damage, difficulty in casting, scarcity and high cost associated with this metal. Among mechanical surface treatments, Deep Cold Rolling (DCR) has been shown to be a very promising process to improve fatigue life by introducing a deep compressive residual stress and work-hardening in the surface layer of components. This process has shown to be superior compared with other surface treatment methods as it yields a better surface quality and induces a deeper residual stress profile which can effectively be controlled through the process parameters (i.e. ball diameter, rolling pressure and feed). However, residual stresses induced through this process at room temperature are generally relaxed upon exposure of the components to elevated operating temperatures. In this work, high-fidelity Finite Element (FE) models have been developed to simulate the DCR process in order to predict the induced residual stresses at room temperature and their subsequent relaxation following exposure to temperature increase. Accuracy of the developed models has been validated using experimental measurements available in the literature. A design optimization strategy has also been proposed to identify the optimal process parameters to maximize the induced beneficial compressive residual stress on and under the surface layer and thus prolong the fatigue life. Conducting optimization directly on the developed high-fidelity FE model is not practical due to high computational cost associated with nonlinear dynamic models. Moreover, responses from the FE models are typically noisy and thus cannot be utilized in gradient based optimization algorithms. In this research study, well-established machine learning principles are employed to develop and validate surrogate analytical models based on the response variables obtained from FE simulations. The developed analytical functions are smooth and can efficiently approximate the residual stress profiles with respect to the process parameters. Moreover the developed surrogate models can be effectively and efficiently utilized as explicit functions for the optimization process. Using the developed surrogate models, conventional (one-sided) DCR process is optimized for a thin Ti64 plate considering the material fatigue properties, operating temperature and external load. It is shown that the DCR process can lead to a tensile balancing residual stress on the untreated side of the component which can have a detrimental effect on the fatigue life. Additionally, application of conventional DCR on thin geometries such as compressor blades can cause manufacturing defects due to unilateral application of the rolling force and can also lead to thermal distortion of the part due to asymmetric profile of the induced residual stresses. Double-sided deep rolling has been shown as a viable alternative to address those issues since both sides of the component are treated simultaneously. The process induces a symmetric residual stress which can be further optimized to achieve a compressive residual stress on both sides of the component. For this case, a design optimization problem is formulated to improve fatigue life in high stress locations on a generic compressor blade. All the optimization problems are formulated for multi-objective functions to achieve most optimal residual stress profiles both at room temperature as well as elevated temperature of 450°C. A hybrid optimization algorithm based on combination of sequential quadratic programming (SQP) technique with stochastic based genetic algorithm (GA) has been developed to accurately catch the global optimum solutions. It has been shown that the optimal solution depends on the stress distribution in the component due to the external load as well as the operating temperature.
Book Synopsis Physics-based Simulation and Reliability Modeling for Multi-objective Optimization of Advanced Cutting Tools in Machining Titanium Alloys by : Mohammad Sima
Download or read book Physics-based Simulation and Reliability Modeling for Multi-objective Optimization of Advanced Cutting Tools in Machining Titanium Alloys written by Mohammad Sima and published by . This book was released on 2015 with total page 257 pages. Available in PDF, EPUB and Kindle. Book excerpt: Titanium alloys are widely used in various industries due to their superior characteristics such as high strength-to-weight ratio, toughness, corrosion resistance and bio-compatibility. Ti-6Al-4V is the most commonly used titanium alloy and considered as difficult-to-cut because of its low thermal conductivity, high chemical reactivity with cutting tool materials at elevated temperatures, and low modulus of elasticity. Therefore, rapid tool wear and poor surface quality are the issues in machining of this alloy. Hence, selecting appropriate cutting conditions (cutting speed, uncut chip thickness, depth of cut, etc.), tool materials, coatings, and geometry are essential not only to increase productivity and decrease the costs, but also to obtain a desirable surface integrity. Initially, a modified constitutive model was proposed for Ti-6Al-4V which is able to predict the behavior under high strains and temperatures. Since workpiece experiences high strain, strain rate at elevated temperatures during machining, it is important to develop a material model that captures material behavior at these conditions. Using this material model, two dimensional finite element simulations were designed to predict machining forces and serrated chip geometry and results were validated with experiments. This verified material model was used in three dimensional finite element simulations to predict tool wear, temperature, stress and strain distributions. Effects of different cutting tool materials, coatings (TiAlN and cBN), geometry and machining process parameters were investigated. A reliability model for different types of cutting tools is created with experimental and physics-based data. Furthermore, using genetic algorithms, a multi-objective optimization problem was designed and solved to find the optimal process parameters (cutting speed and feed) and cutting tool selection in order to maximize reliability and machining efficiency. Finally, validation experiments were conducted to measure tool wear on uncoated and TiAlN coated inserts under the optimum cutting conditions with expected reliability rating. The results indicate that there is an adequate agreement and the discrepancy may be related to model uncertainty and stochastic nature of the tool wear.
Book Synopsis Effects of Machining Parameters and Cooling Strategies on Cutting Forces and Surface Integrity in High-speed Slot End-milling of Titanium Alloy by : Emenike Nick Chukwuma
Download or read book Effects of Machining Parameters and Cooling Strategies on Cutting Forces and Surface Integrity in High-speed Slot End-milling of Titanium Alloy written by Emenike Nick Chukwuma and published by . This book was released on 2013 with total page 155 pages. Available in PDF, EPUB and Kindle. Book excerpt: "Paper 1 presents the results of the investigations of the effects of cooling strategies [Emulsion cooling, Minimum Quantity Lubrication (MQL) and Liquid Nitrogen (LN2)] and machining parameters (feed rate and spindle speed) on cutting force components, cutting temperature and tool wear during slot end-milling of titanium Ti-6Al-4V workpiece. All machining experiments were conducted using four-flute 0.5 inch diameter uncoated solid carbide end-mill on Cincinnati Milacron, Sabre 750 vertical machining center equipped with Acramatic 2100 controller. Cutting force components were acquired and tool wear was indirectly measured from maximum cutting force variation per slot from the first pass to the eighth pass. The experimental results show that spindle speed and cooling strategies are the most significant factors that reduce cutting forces and tool wear, while cryogenic cooling, low spindle speed and high feed rate reduce cutting temperature. In paper 2, the results of the investigations on the effects of cooling strategies and machining parameters on surface roughness and residual stresses during slot end-milling of titanium alloy workpiece are presented. From the results obtained, combination of MQL and LN2 (MQL+LN2) was best in reducing surface roughness both on the web and on the rib. The combination of MQL and LN2 was the best in producing the most compressive residual stresses on the surface of the left rib while LN2 cooling strategy alone was the worst with high tensile residual stress on the surface of the left rib"--Abstract, page iv.
Book Synopsis An Experimental Study and Parameters Optimization on Duplex Turning of Titanium Alloy by : Ravindra Nath Yadav
Download or read book An Experimental Study and Parameters Optimization on Duplex Turning of Titanium Alloy written by Ravindra Nath Yadav and published by . This book was released on 2018 with total page 22 pages. Available in PDF, EPUB and Kindle. Book excerpt: The present article focuses on analyzing the cutting behavior of the duplex turning process for turn-cut machining of aerospace material, especially for titanium alloy. The experiments are conducted on a homemade setup that was mounted on a lathe machine. Each experiment was replicated twice to avoid variability, and a total of 31 experimental data are collected according to the Central Composite Rotating Design matrix. The feed rate, cutting velocity, and depth of cuts (primary and secondary) are taken as control parameters, while the average surface roughness, primary cutting force, and secondary cutting force are taken as response parameters. The experimental data are used to develop an empirical model using Response Surface Methodology (RSM). The developed RSM model has been experimentally tested and used to generate the response surfaces for parametric studies. Finally, the responses are optimized using D-optimality criteria, and the optimal results are experimentally validated. The result shows that RSM models are well fitted with experimental values with percentage errors of 5.03, 4.77, and 4.87 % for the Fp, Fs, and Ra, respectively. Furthermore, the optimal cutting condition shows significant improvement in the responses, i.e., 4.22, 3.72, and 2.85 % for the Fp, Fs, and Ra, respectively.
Book Synopsis Optimization of Micro-end Milling Process Parameters of Titanium Alloy Using Non-dominated Sorting Genetic Algorithm by : Abolfazl Golshan
Download or read book Optimization of Micro-end Milling Process Parameters of Titanium Alloy Using Non-dominated Sorting Genetic Algorithm written by Abolfazl Golshan and published by . This book was released on 2013 with total page 170 pages. Available in PDF, EPUB and Kindle. Book excerpt:
Book Synopsis A Study of High-speed Milling of Titanium Alloys by : Lester Vern Colwell
Download or read book A Study of High-speed Milling of Titanium Alloys written by Lester Vern Colwell and published by . This book was released on 1961 with total page 105 pages. Available in PDF, EPUB and Kindle. Book excerpt:
Book Synopsis Evaluation of End Milling Titanium Alloy Ti-6A1-4V Using Finite Element Method by : Rouzbeh Ahmadianchashmi
Download or read book Evaluation of End Milling Titanium Alloy Ti-6A1-4V Using Finite Element Method written by Rouzbeh Ahmadianchashmi and published by . This book was released on 2012 with total page 126 pages. Available in PDF, EPUB and Kindle. Book excerpt:
Book Synopsis Flow stress model for Titanium Alloy Ti-6Al-4V in machining operations by : Alejandro Martínez López
Download or read book Flow stress model for Titanium Alloy Ti-6Al-4V in machining operations written by Alejandro Martínez López and published by . This book was released on 2009 with total page 234 pages. Available in PDF, EPUB and Kindle. Book excerpt: Machining of titanium alloys is widely used in high-value added industries such as aerospace and medical devices. In this research, an extensive literature review was conducted on experimental and simulation investigations of Ti-6Al-4V machining. Using the findings of the review and applying a novel experimental technique (slotmilling test), an approach to determine the flow stress behavior for the Finite Element Modeling (FEM) of titanium machining was developed and implemented. An evaluation of the proposed model in this study is addressed using experimental data from literature and from slot-milling tests conducted during this research. The proposed flow stress model for Ti-6Al-4V shows good prediction capabilities in regards to chip morphology and cutting forces. The typical serrated chip found in titanium machining is reproduced in this research through FEM simulation and without the need of a damage criterion. This phenomenon can be reproduced through adiabatic softening captured by the developed constitutive model. The proposed flow stress model is based on a Johnson-Cook formulation and modified to use only 4 calibration parameters. Based on these results, FEM simulation is an effective tool for modeling of titanium (Ti-6Al-4V) machining, in order to minimize the use of costly experimentation. The applicability of the multi-scale modeling approach is also shown in this research. Dynamic stability of machining operations and FEM simulations are linked through a non-linear cutting force model. This research shows how FEM simulation in titanium alloys can be applied to generate the parameters of the non-linear cutting force model.
Download or read book Metals Abstracts written by and published by . This book was released on 1998 with total page 1076 pages. Available in PDF, EPUB and Kindle. Book excerpt:
Book Synopsis Modelling of the Machining Process of a Nickel-Titanium Based Shape Memory Alloy by : Mehrshad Mehrpouya
Download or read book Modelling of the Machining Process of a Nickel-Titanium Based Shape Memory Alloy written by Mehrshad Mehrpouya and published by . This book was released on 2017-03-02 with total page 126 pages. Available in PDF, EPUB and Kindle. Book excerpt: Master's Thesis from the year 2013 in the subject Engineering - Mechanical Engineering, grade: 3.6/4, Universiti Putra Malaysia (University Putra Malaysia (UPM)), course: Master of Manufacturing Engineering, language: English, abstract: One of the aims of this study is to optimize machining of nickel based shape memory alloys. Nickel-titanium (Nitinol) is a famous shape memory material which is applied in a wide range of products especially in aerospace, medical, and biomedical. The main issue in this project is related to the materials which cannot be machined easily, high tool wear, high cutting force, huge hardness and surface defects add many problems to their machining. Experimental studies were compared with simulations in this report and the main section of that is the optimum cutting speed of nickel-titanium machining would be obtained. Experimental studies show that the cutting speed of machining of nickel-titanium alloy might be around 100 m/min, because the tool wear and cutting force are in minimum condition. In this study, by applying ANSYS software based on the finite element method, the optimum speed of machining process could be guessed around 100 m/min. Cutting speed-Stress diagram in the modeling results have confirmed the same cutting speed in machining process of NiTi in compare with experimental results.
