FEM based mathematical modelling of thrust force during drilling of Al7075-T6

Like most machining processes, drilling is affected by many parameters such as the tool diameter, the cutting speed and feed. The current research investigates the possibility of developing a finite element modelling based prediction model for the generated thrust force during drilling of Al7075-T6 with solid carbide tools. A total of 27 drilling experiments were carried out in order to examine the interaction between three key parameters and their effect on thrust force. In addition, simulations of the experiments were realized with the use of DEFORM3D((TM))software in order to obtain the necessary numerical data. Finally, a comparison was made between the experimental and the numerical results to verify that reliable modelling is feasible. The mathematical model was acquired with the use of response surface methodology and the verification of the adequacy of the model was performed through an analysis of variance. The majority of the simulations yielded results in agreement with the experimental results at around 95% and the derived model offered an accuracy of 5.9%

Influence of the Nose Radius on the Machining Forces Induced during AISI-4140 Hard Turning: A CAD-Based and 3D FEM Approach

The present study investigated the performance of three ceramic inserts in terms of the micro-geometry (nose radius and cutting edge type) with the aid of a 3D finite element (FE) model. A set of nine simulation runs was performed according to three levels of cutting speed and feed rate with respect to a predefined depth of cut and tool nose radius. The yielded results were compared to the experimental values that were acquired at identical cutting conditions as the simulated ones for verification purposes. Consequently, two more sets of nine simulations each were carried out so that a total of 27 turning simulation runs would adduce. The two extra sets corresponded to the same cutting conditions, but to different cutting tools (with varied nose radius). Moreover, a prediction model was established based on statistical methodologies such as the response surface methodology (RSM) and the analysis of variance (ANOVA), further investigating the relationship between the critical parameters (cutting speed, feed rate, and nose radius) and their influence on the generated turning force components. The comparison between the experimental values of the cutting force components and the simulated ones demonstrated an increased correlation that exceeded 89%. Similarly, the values derived from the statistical model were in compliance with the equivalent FE model values due to the verified adequacy

CAD-Based Automated Design of FEA-Ready Cutting Tools

The resources of modern Finite Element Analysis (FEA) software provide engineers with powerful mechanisms that can be used to investigate numerous machining processes with satisfying results. Nevertheless, the success of a simulation, especially in three dimensions, relies heavily on the accuracy of the cutting tool models that are implemented in the analyses. With this in mind, the present paper presents an application developed via Computer-Aided Design (CAD) programming that enables the automated design of accurate cutting tool models that can be used in 3D turning simulations. The presented application was developed with the aid of the programming resources of a commercially available CAD system. Moreover, the parametric design methodology was employed in order to design the tools according to the appropriate standards. Concluding, a sample tool model was tested by performing a number of machining simulations based on typical cutting parameters. The yielded results were then compared to experimental values of the generated machining force components for validation. The findings of the study prove the functionality of the tool models since a high level of agreement occurred between the acquired numerical results and the experimental ones

CAD-based 3D-FE modelling of AISI-D3 turning with ceramic tooling

In this study, the development of a 3D Finite Element (FE) model for the turning of AISI-D3 with ceramic tooling is presented, with respect to four levels of cutting speed, feed, and depth of cut. The Taguchi method was employed in order to create the orthogonal array according to the variables involved in the study, reducing this way the number of the required simulation runs. Moreover, the possibility of developing a prediction model based on well-established statistical tools such as the Response Surface Methodology (RSM) and the Analysis of Variance (ANOVA) was examined, in order to further investigate the relationship between the cutting speed, feed, and depth of cut, as well as their influence on the produced force components. The findings of this study point out an increased correlation between the experimental results and the simulated ones, with a relative error below 10% for most tests. Similarly, the values derived from the developed statistical model indicate a strong agreement with the equivalent numerical values due to the verified adequacy of the statistical model

Engineering applications using CAD based application programming interface

Automating the design process of a product or a system can provide engineers and designers with many benefits. As such, repeatable tasks that are time consuming can be handled automatically and with minimal human attention. This is achieved by using the API (Application Programmable Interface) of CAD systems in order to create macros or even develop software applications. The present paper deals with an application that has been developed with the API of a general purposes CAD system. This application automates the design process of a standard pneumatic double acting cylinder based on the appropriate inserted parameters (ISO 15552).The design process begins with the creation of a series of components developed as solids, and extends to the extraction of basic attributes and properties from the complete mechanical assembly. Finally, the assembled models and the extracted data can be used to further study the design of the pneumatic double acting cylinder. It is expected in the future to expand the features of the presented application in order to automate the design process of other related mechanical systems