On the turning modeling and simulation: 2D and 3D FEM approaches
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Date
2014
Journal Title
Journal ISSN
Volume Title
Publisher
Mechanics & Industry
Abstract
For qualitative prediction of chip morphology and quantitative prediction of burr size, 2D and
3D finite element (FE) based turning models have been developed in this paper. Coupled temperaturedisplacement
machining simulations exploiting the capabilities of Abaqus r
with a particular industrial
turning insert and a newly proposed geometrical version of this insert have been performed. Limitations of
2D models in defining the chip morphologies and surface topologies have been discussed. The phenomenological
findings on the Poisson burr (Side burr) formation using 3D cutting models have been highlighted.
Bespoke geometry of the turning insert has been found helpful in reducing the Poisson burr formation, as
it reduces the contact pressures at the edges of tool rake face-workpiece interface. Lower contact pressures
serve to decrease the material flow towards workpiece edges (out of plane deformation). In contrast, higher
contact pressures at tool rake face-workpiece interface lead to more material flow towards workpiece edges
resulting in longer burr. Simulation results of chip morphologies and cutting forces for turning an aluminum
alloy A2024-T351 have been compared with the experimental ones. Finally, it has been concluded that
the newly proposed geometry of the insert not only decreases the burr but also helpful in lessening the
magnitude of tool-workpiece initial impact.
Description
Keywords
Orthogonal turning, FE model, poisson burr formation, chip morphology, A2024-T351
Citation
Asad, M., Mabrouki, T., Ijaz, H., Khan, M. A., & Saleem, W. (2014). On the turning modeling and simulation: 2D and 3D FEM approaches, Mechanics & Industry , 15 5 (2014) 427-434