Numerical Modelling, Simulation, and Analysis of the End-Milling Process Using DEFORM-3D with Experimental Validation
In this present work, finite element analysis (FEA)-based simulation of end-milling of AISI1045 steel using tungsten carbide tool was performed using DEFORM-3D simulation software. Usui tool wear model, Johnson-cook material model and adaptive remeshing are considered during machining simulation. Th...
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| Format: | Article |
| Language: | English |
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Wiley
2022-01-01
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| Series: | Advances in Materials Science and Engineering |
| Online Access: | http://dx.doi.org/10.1155/2022/5692298 |
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| author | B. Deepanraj N. Senthilkumar G. Hariharan T. Tamizharasan Tesfaye Tefera Bezabih |
| author_facet | B. Deepanraj N. Senthilkumar G. Hariharan T. Tamizharasan Tesfaye Tefera Bezabih |
| author_sort | B. Deepanraj |
| collection | DOAJ |
| description | In this present work, finite element analysis (FEA)-based simulation of end-milling of AISI1045 steel using tungsten carbide tool was performed using DEFORM-3D simulation software. Usui tool wear model, Johnson-cook material model and adaptive remeshing are considered during machining simulation. The impact of machining variables rate of feed, tool speed, and depth of cut was investigated, and the best integration of variables was distinguished for lower cutting temperature, principal stress, cutting forces, effective stresses, tool wear, and effective strain. The obtained results were correlated using experimentation in a vertical machining center attached with a Kistler tool dynamometer with data acquisition setup for capturing the cutting forces, and an infrared (IR) thermometer was used to measure the cutting temperature, and a comparison was done. Results showed a good correlation. There is a relationship between experimental and numerical results, and simulation findings can be utilised for interpreting the influence of machining parameters. |
| format | Article |
| id | doaj-art-4301a27a3b0a429a9f0efea81fea4c03 |
| institution | Kabale University |
| issn | 1687-8442 |
| language | English |
| publishDate | 2022-01-01 |
| publisher | Wiley |
| record_format | Article |
| series | Advances in Materials Science and Engineering |
| spelling | doaj-art-4301a27a3b0a429a9f0efea81fea4c032025-02-03T05:50:36ZengWileyAdvances in Materials Science and Engineering1687-84422022-01-01202210.1155/2022/5692298Numerical Modelling, Simulation, and Analysis of the End-Milling Process Using DEFORM-3D with Experimental ValidationB. Deepanraj0N. Senthilkumar1G. Hariharan2T. Tamizharasan3Tesfaye Tefera Bezabih4Department of Mechanical EngineeringSaveetha School of EngineeringUniversity College of Engineering (Anna University)SRM TechnologiesDepartment of Mechanical EngineeringIn this present work, finite element analysis (FEA)-based simulation of end-milling of AISI1045 steel using tungsten carbide tool was performed using DEFORM-3D simulation software. Usui tool wear model, Johnson-cook material model and adaptive remeshing are considered during machining simulation. The impact of machining variables rate of feed, tool speed, and depth of cut was investigated, and the best integration of variables was distinguished for lower cutting temperature, principal stress, cutting forces, effective stresses, tool wear, and effective strain. The obtained results were correlated using experimentation in a vertical machining center attached with a Kistler tool dynamometer with data acquisition setup for capturing the cutting forces, and an infrared (IR) thermometer was used to measure the cutting temperature, and a comparison was done. Results showed a good correlation. There is a relationship between experimental and numerical results, and simulation findings can be utilised for interpreting the influence of machining parameters.http://dx.doi.org/10.1155/2022/5692298 |
| spellingShingle | B. Deepanraj N. Senthilkumar G. Hariharan T. Tamizharasan Tesfaye Tefera Bezabih Numerical Modelling, Simulation, and Analysis of the End-Milling Process Using DEFORM-3D with Experimental Validation Advances in Materials Science and Engineering |
| title | Numerical Modelling, Simulation, and Analysis of the End-Milling Process Using DEFORM-3D with Experimental Validation |
| title_full | Numerical Modelling, Simulation, and Analysis of the End-Milling Process Using DEFORM-3D with Experimental Validation |
| title_fullStr | Numerical Modelling, Simulation, and Analysis of the End-Milling Process Using DEFORM-3D with Experimental Validation |
| title_full_unstemmed | Numerical Modelling, Simulation, and Analysis of the End-Milling Process Using DEFORM-3D with Experimental Validation |
| title_short | Numerical Modelling, Simulation, and Analysis of the End-Milling Process Using DEFORM-3D with Experimental Validation |
| title_sort | numerical modelling simulation and analysis of the end milling process using deform 3d with experimental validation |
| url | http://dx.doi.org/10.1155/2022/5692298 |
| work_keys_str_mv | AT bdeepanraj numericalmodellingsimulationandanalysisoftheendmillingprocessusingdeform3dwithexperimentalvalidation AT nsenthilkumar numericalmodellingsimulationandanalysisoftheendmillingprocessusingdeform3dwithexperimentalvalidation AT ghariharan numericalmodellingsimulationandanalysisoftheendmillingprocessusingdeform3dwithexperimentalvalidation AT ttamizharasan numericalmodellingsimulationandanalysisoftheendmillingprocessusingdeform3dwithexperimentalvalidation AT tesfayeteferabezabih numericalmodellingsimulationandanalysisoftheendmillingprocessusingdeform3dwithexperimentalvalidation |