Finite element analysis of sheet metal formability effect on automotive part

An increasing demand for lower price and better quality vehicle has increase complexity of tool development process. This includes concept evaluation, design phase, prototype phase and pre production phase. Experience show that R&D spends most of the time and cost for tool development process, which includes assembly tooling, product tooling for automobile sheet metal component or part requires the highest cost in tool development process as most metal stamping part requires more than one tool to produce finished stamping part. For these reason, sheet metal forming simulation and analysis at early stage of tool development process is very important to shorten the tool development cycle time and cost. In other word by applying sheet metal forming simulation and analysis at early stage it can reduce the die manufacturing cycle time and cost

Surface roughness of hypereutectic Al-Si A390 in high speed milling

The most important measures of surface quality during the machining process is the average surface roughness (Ra), and it is mostly caused by machining parameters, such as cutting speed, feed rate, depth of cut, etc. This paper presents the effect of cutting parameters on surface roughness for a cutting speed of 900 to 1700 m/min, feed rate of 0.02 to 0.06 mm/tooth and depth of cut of 0.2 to 0.4mm. The analysis of variance (ANOVA) is applied to determine the effects of the machining parameters on the surface roughness, later the mathematical model for the surface roughness was developed. From the ANOVA, it was found that cutting speed and feed rate were the significant factors that affecting the surface roughness. The optimum condition for machining parameter was suggested by the Design Expert software when machining at cutting speed of 1490 mm/min, feed rate of 0.03 mm/tooth and depth of cut at 0.29 mm. At this cutting parameter the surface roughness value is predicted at 0.24µm which is similar with the surface roughness than can be obtained using manual grinding

Sustainable High-Speed Milling of Magnesium Alloy AZ91D in Dry and Cryogenic Conditions

Magnesium alloy AZ91D is used extensively in the automotive industry because of its high strength-to-weight ratio. Typically, components produced using the alloy are required to have good surface finish and to contribute to high productivity but require long cutting times. Cryogenic cooling is an environmentally friendly technology which has been proven to improve cutting tool life and surface finish. This paper presents an investigation on the effects of dry and cryogenic cutting conditions at a high cutting speed regime for milling of magnesium alloy. This study focused on a high-speed regime due to the chips of magnesium alloy being highly combustible and an effective means of decreasing the temperature in the cutting zone was of great concern. The machining experiment was carried out using uncoated carbide end milling utilizing a full factorial design (L16) with cutting speeds of 900 m/min and 1300 m/min, feed rate of 0.02 mm/tooth and 0.05 mm/tooth, axial depth of cut at 0.2 mm and 0.3 mm, and radial depth of cut at 10 mm and 40 mm. For dry machining, the longest tool life at flank wear (VBmax) of 0.21 mm was at 30 min, which was obtained at cutting speeds of 1300 m/min, feed rate of 0.02 mm/tooth, axial depth of cut at 0.2 mm, and radial depth of cut at 40 mm. Using this cutting condition, a mirror-like surface of 0.106 µm was produced. For machining under cryogenic condition at VBmax of 0.2 mm, the maximum tool life of 1864 min was achieved at a cutting speed of 900 m/min, feed rate of 0.02 mm/tooth, axial depth of cut of 0.3 mm, and radial depth of cut of 40 mm. Under this cutting condition, a lower surface finish of 0.091 µm was obtained. It can be concluded that the application of liquid nitrogen (LN2) is very effective in enhancing the tool life and in obtaining a better-machined surface, especially at a lower cutting speed of 900 m/min. A longer tool life and high-quality machined parts will significantly improve the productivity and cost savings in the related industry

Surface Roughness Of Magnesium Alloy AZ91D In High Speed Milling

Magnesium alloy is a material with a high strength to weight ratio and is suitable for various applications such as in automotive, aerospace, electronics, industrial, biomedical and sports. Most end products require a mirror-like finish, therefore, this paper will present how a mirror-like finishing can be achieved using a high speed face milling that is equivalent to the manual polishing process. The high speed cutting regime for magnesium alloy was studied at the range of 900-1400 m/min, and the feed rate for finishing at 0.03-0.09 mm/tooth. The surface roughness found for this range of cutting parameters were between 0.061-0.133 μm, which is less than the 0.5μm that can be obtained by manual polishing. Furthermore, from the S/N ratio plots, the optimum cutting condition for the surface roughness can be achieved at a cutting speed of 1100 m/min, feed rate 0.03 mm/tooth, axial depth of cut of 0.20 mm and radial depth of cut of 10 mm. From the experimental result the lowest surface roughness of 0.061μm was obtained at 900 m/min with the same conditions for other cutting parameters. This study revealed that by milling AZ91D at a high speed cutting, it is possible to eliminate the polishing process to achieve a mirror-like finishing

Optimization of tool life and surface roughness for hypereutectic Al – si alloys in face milling / Kamal Othman...[et al.]

machining processes for automotive components. This study intends to investigate the machining parameters affecting the machinability of hypereutectic Al-Si alloys in the context of surface roughness and tool life via a DLC coated face milling cutter inserted under dry cutting conditions. The machining parameters used in this study were cutting speeds of 250 m/min and 350 m/min, feed rates of 0.02 mm/tooth and 0.04 mm/tooth, and a constant depth of cut of 0.3 mm. The orthogonal full factorial (2³) method was used for the experimental trials. A commercial software called Minitab 17 was used to generate the analysis of variance (ANOVA) and the mathematical prediction model for each machining response. The experimental results confirmed that an excellent surface finish was achieved with a value of as low as 0.140 μm, while the highest value for tool life of 105.47 minute was realized with face milled aluminium alloy A390. From the analyses, it was confirmed that the feed rate is the most significant machining factor affecting surface roughness, while in the case of tool life; cutting speed is the most influential machining factor. The main effect plot showed that the optimum cutting condition for realizing low surface roughness and longer tool life is at 250 m/min, a feed rate of 0.02 mm/tooth, and radial depth of cut 12.5 mm. The prediction model for surface roughness and tool life was developed and reported low percentage errors