Araştırma Makalesi
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Yıl 2023, Cilt: 27 Sayı: 3, 697 - 707, 30.06.2023

Yasin Furkan Görgülü Murat Aydın

https://doi.org/10.16984/saufenbilder.1245764

Öz

Anahtar Kelimeler

Ansys deformation end mill explicit dynamics stress and strain

Kaynakça

  • I. Rajpoot, S. N. Siddique, “Investigation and numerical analysis of milling cutter,” International Research Journal of Engineering and Technology (IRJET), vol. 05, no. 06, pp. 1508–1513, 2018.
  • V. Kumar, A. Eakambaram, A. Arivazhagan, “FEM analysis to optimally design end mill cutters for milling of Ti-6Al-4V,” Procedia Engineering, vol. 97, pp. 1237–1246, 2014.
  • D. V. Evdokimov, D. G. Fedorov, D. L. Skuratov, “Thermal stress resarch of processing and formation of residual stress when end milling of a workpiece,” World Applied Sciences Journal, vol. 31, no. 1, pp. 51–55, 2014.
  • W. Ma, R. Wang, X. Zhou, X. Xie, “The finite element analysis–based simulation and artificial neural network–based prediction for milling processes of aluminum alloy 7050,” Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, vol. 235, no. 1–2, pp. 265–277, 2021.
  • M. A. Oymak, E. Bahçe, İ. Gezer, “Investigation Of Cryogenic Cooling Effect With Finite Element Method In Micro Milling Of Ti6al4v Material,” International Journal of Innovative Engineering Applications, 2021.
  • K. K. Kumar, N. Srinivas, “Optimization and Process Control in Small Diameter End Mill,” International Journal of Engineering Science and Computing, vol. 6, no. 8, pp. 2581–2585, 2016.
  • P. Praveen Raj, A. Elaya Perumal, “Prediction of Delamination in End Milling of GFRP Using ANSYS,” Asian International Journal of Science and Technology in Production and Manufacturing Engineering, vol. 6, no. 2, pp. 39–46, 2013.
  • A. C. Araujo, A. M. Savi, P. M. L. C. Pacheco, “Experimental and Numerical Analysis of End Milling,” in VI National Congress of Mechanical Engineering, 2010.
  • S. S. Prassad, C. Sreedhar, “Finate Element Analysis of Multi Point Cutting Tool,” ANVESHANA’s International Journal of Research in Engineering and Applied Sciences, vol. 1, no. 11, pp. 123–135, 2016.
  • M. Dragicevic, S. Jozic, D. Bajic, “Finite element simulation of stresses distribution and tool displacement in the cutting tool during hard nd-milling in different machining conditions,” in Mechanical Technology and Structural Materials, 2017, vol. 2017, no. 55, pp. 29–36.
  • S. S. Karidkar, V. A. Patankar, “Finite Element Modeling and Simulation of Thin Wall Machining of Al 8011,” International Journal of Engineering Research and Technology, vol. 10, no. 1, pp. 654–658, 2017.
  • Y. Işık, E. Öztürk, “Experimental Analysis of Cutting Forces and Finite Element Simulation in Milling Operations,” International Journal of Mechanical Engineering, vol. 8, no. 11, pp. 1–7, 2021.
  • V. Kumar, R. N. Mall, “Analysis and Modelling of Single Point Cutting Tool with help of ANSYS for Optimization of Vibration Parameter,” International Journal for Scientific Research & Development, vol. 3, no. 9, pp. 175–177, 2015.
  • R. Shetty, K. Laxmikant, R. Pai, S. S. Rao, “Finite element modeling of stress distribution in the cutting path in machining of discontinuously reinforced aluminium composites,” ARPN Journal of Engineering and Applied Sciences, vol. 3, no. 4, pp. 25–31, 2008.
  • N. H. Kim, D. Won, J. C. Ziegert, “Numerical analysis and parameter study of a mechanical damper for use in long slender endmills,” International Journal of Machine Tools and Manufacture, vol. 46, no. 5, pp. 500–507, 2006.
  • K. B. Mustapha, Z. W. Zhong, “A new modeling approach for the dynamics of a micro end mill in high-speed micro-cutting,” JVC/Journal of Vibration and Control, vol. 19, no. 6, pp. 901–923, 2013.
  • D. R. Pradica, Andoko, D. Z. Lubis, “Simulation on the spindle of a five-axis multifunctional CNC machine using finite element method,” IOP Conference Series: Materials Science and Engineering, vol. 1034, no. 1, p. 012017, 2021.
  • Q. Liu, H. Xu, J. Wang, “Analysis of four-edge mill modality and stress deformation based on ANSYS,” Journal of Physics: Conference Series, vol. 1939, no. 1, 2021.
  • P. Tandon, M. Rajik Khan, “Three dimensional modeling and finite element simulation of a generic end mill,” CAD Computer Aided Design, vol. 41, no. 2, pp. 106–114, 2009.
  • L. Yang, M. L. Zheng, “Simulation and analysis of ball-end milling of panel moulds based on deform 3D,” International Journal of Simulation Modelling, vol. 16, no. 2, pp. 343–356, 2017.
  • W. Nie, M. Zheng, S. Xu, Y. Liu, H. Yu, “Design and Optimization of Variable Pitch End Mills Based on Dynamic Balance Accuracy,” 2021.
  • X. X. Wang, X. H. Lu, G. H. Xu, F. C. Wang, “The finite element analysis of the stress and deformation of the micro-milling cutter based on ANSYS,” Applied Mechanics and Materials, vol. 494–495, pp. 345–348, 2014.
  • M. Madajewski, S. Wojciechowski, N. Znojkiewicz, P. Twardowski, “Hybrid numerical-analytical model for force prediction in end milling,” Mechanik, vol. 91, no. 8–9, pp. 757–759, 2018.
  • D. Steinberg, Equation of state and strength properties of selected materials. Lawrence Livermore National Laboratory, 1996.
  • Conical Cutting Tools, “Choosing the Correct Angle End Mill For Your Job,” 2023. https://conicalendmills.com/ordering/selection-guide/helical-angle-selection/ (accessed Feb. 16, 2023).
  • M. Melchiorre, T. Duncan, “The Fundamentals of FEA Meshing for Structural Analysis,” 2021. https://www.ansys.com/blog/fundamentals-of-fea-meshing-for-structural-analysis (accessed Jul. 04, 2022).
  • A. A. Carvalho, “Tips and Tricks for Explicit Simulations,” 2019.
  • Ansys Inc., “Introduction to Ansys Meshing.” Ansys Inc., pp. L5-16, 2011.
  • Ansys Inc., “Mesh Quality And Advanced Topics Ansys Workbench 16.0,” 2015.
  • A. Cambaz, Y. F. Gorgulu, H. Arat, “Analysing fluid-structure interaction with CFD and FEA on a marine double-wall LNG piping system,” Multidisciplinary Scientific Journal of Maritime Research, vol. 36, no. 1, pp. 51–60, 2022.
  • A. Cambaz, Y. F. Görgülü, H. Arat, “Two-Phase Numerical Modelling of a Wet Exhaust System in a Catamaran Motor Yacht Diesel Engine,” European Journal of Science and Technology, vol. 31, no. Supp. 1, pp. 165–170, 2021.
  • Y. F. Görgülü, M. A. Özgür, R. Köse, “NACA 0009 Profilli Bir Kanadin Düşük Bir Reynolds Sayisinda Had Analizi,” Journal of Polytechnic, vol. 0900, no. 3, pp. 1237–1242, 2021.
  • A.L.M.T Corp., “Formula to calculate cutting process,” 2022. https://www.allied-material.co.jp/en/products/diamond/knowledge/cutting_formula.html (accessed Jul. 04, 2022).
  • Helical Solutions, Machining Guidebook. 2016.
  • J. R. Walker, B. Dixon, Machining Fundamentals, 10th ed. The Goodheart-Willcox Company, Inc., 2019.
  • E. Oberg, F. D. Jones, H. L. Horton, H. H. Ryffel, C. J. McCauley, Machinery’s Handbook, 31st ed. Industrial Press, Inc., 2020.

Estimating the Strength and Deformation Properties of the End Milling Process Using Numerical Analysis Methods

Yıl 2023, Cilt: 27 Sayı: 3, 697 - 707, 30.06.2023

Yasin Furkan Görgülü Murat Aydın

https://doi.org/10.16984/saufenbilder.1245764

Öz

In the study, the end mill made of titanium material and having a unique design with a 4-flute was simulated during the milling of the workpiece with a geometry of a rectangular prism made of aluminum material. Ansys Explicit Dynamics was used in the study. Modeling and simulation of the milling process were made with finite element analysis for the estimation of the strength properties. The end mill is chosen as a titanium alloy, while the milled workpiece is aluminum. All parameters were kept constant and only the depth of cut was examined in three scenarios 3, 6, and 9 mm. The simulations were carried out by taking the spindle speed of 4000 RPM and the feeding rate of 3350 mm/s. One of the conveniences provided by Explicit Dynamics is that it can be solved in very small time intervals, and for this reason, the time step in the analysis is solved by taking 0.001 seconds. While hexahedral mesh is applied to the tool, a tetrahedral mesh is applied to the workpiece. The generated mesh has 8,012 nodes and 17,052 mesh elements. Average deformations for both tool and workpiece are 36.92, 38.10, and 38.29 mm, respectively. Strain also shows a similar trend to the total deformation and the average values for all three scenarios were found to be 2.84 x 10-3, 4.43 x 10-3 and 3.99 x 10-3 mm/mm. Also, the stress values were obtained as 78.23, 76.83, and 77.99 MPa.

Anahtar Kelimeler

Ansys deformation end mill explicit dynamics stress and strain.

Kaynakça

  • I. Rajpoot, S. N. Siddique, “Investigation and numerical analysis of milling cutter,” International Research Journal of Engineering and Technology (IRJET), vol. 05, no. 06, pp. 1508–1513, 2018.
  • V. Kumar, A. Eakambaram, A. Arivazhagan, “FEM analysis to optimally design end mill cutters for milling of Ti-6Al-4V,” Procedia Engineering, vol. 97, pp. 1237–1246, 2014.
  • D. V. Evdokimov, D. G. Fedorov, D. L. Skuratov, “Thermal stress resarch of processing and formation of residual stress when end milling of a workpiece,” World Applied Sciences Journal, vol. 31, no. 1, pp. 51–55, 2014.
  • W. Ma, R. Wang, X. Zhou, X. Xie, “The finite element analysis–based simulation and artificial neural network–based prediction for milling processes of aluminum alloy 7050,” Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, vol. 235, no. 1–2, pp. 265–277, 2021.
  • M. A. Oymak, E. Bahçe, İ. Gezer, “Investigation Of Cryogenic Cooling Effect With Finite Element Method In Micro Milling Of Ti6al4v Material,” International Journal of Innovative Engineering Applications, 2021.
  • K. K. Kumar, N. Srinivas, “Optimization and Process Control in Small Diameter End Mill,” International Journal of Engineering Science and Computing, vol. 6, no. 8, pp. 2581–2585, 2016.
  • P. Praveen Raj, A. Elaya Perumal, “Prediction of Delamination in End Milling of GFRP Using ANSYS,” Asian International Journal of Science and Technology in Production and Manufacturing Engineering, vol. 6, no. 2, pp. 39–46, 2013.
  • A. C. Araujo, A. M. Savi, P. M. L. C. Pacheco, “Experimental and Numerical Analysis of End Milling,” in VI National Congress of Mechanical Engineering, 2010.
  • S. S. Prassad, C. Sreedhar, “Finate Element Analysis of Multi Point Cutting Tool,” ANVESHANA’s International Journal of Research in Engineering and Applied Sciences, vol. 1, no. 11, pp. 123–135, 2016.
  • M. Dragicevic, S. Jozic, D. Bajic, “Finite element simulation of stresses distribution and tool displacement in the cutting tool during hard nd-milling in different machining conditions,” in Mechanical Technology and Structural Materials, 2017, vol. 2017, no. 55, pp. 29–36.
  • S. S. Karidkar, V. A. Patankar, “Finite Element Modeling and Simulation of Thin Wall Machining of Al 8011,” International Journal of Engineering Research and Technology, vol. 10, no. 1, pp. 654–658, 2017.
  • Y. Işık, E. Öztürk, “Experimental Analysis of Cutting Forces and Finite Element Simulation in Milling Operations,” International Journal of Mechanical Engineering, vol. 8, no. 11, pp. 1–7, 2021.
  • V. Kumar, R. N. Mall, “Analysis and Modelling of Single Point Cutting Tool with help of ANSYS for Optimization of Vibration Parameter,” International Journal for Scientific Research & Development, vol. 3, no. 9, pp. 175–177, 2015.
  • R. Shetty, K. Laxmikant, R. Pai, S. S. Rao, “Finite element modeling of stress distribution in the cutting path in machining of discontinuously reinforced aluminium composites,” ARPN Journal of Engineering and Applied Sciences, vol. 3, no. 4, pp. 25–31, 2008.
  • N. H. Kim, D. Won, J. C. Ziegert, “Numerical analysis and parameter study of a mechanical damper for use in long slender endmills,” International Journal of Machine Tools and Manufacture, vol. 46, no. 5, pp. 500–507, 2006.
  • K. B. Mustapha, Z. W. Zhong, “A new modeling approach for the dynamics of a micro end mill in high-speed micro-cutting,” JVC/Journal of Vibration and Control, vol. 19, no. 6, pp. 901–923, 2013.
  • D. R. Pradica, Andoko, D. Z. Lubis, “Simulation on the spindle of a five-axis multifunctional CNC machine using finite element method,” IOP Conference Series: Materials Science and Engineering, vol. 1034, no. 1, p. 012017, 2021.
  • Q. Liu, H. Xu, J. Wang, “Analysis of four-edge mill modality and stress deformation based on ANSYS,” Journal of Physics: Conference Series, vol. 1939, no. 1, 2021.
  • P. Tandon, M. Rajik Khan, “Three dimensional modeling and finite element simulation of a generic end mill,” CAD Computer Aided Design, vol. 41, no. 2, pp. 106–114, 2009.
  • L. Yang, M. L. Zheng, “Simulation and analysis of ball-end milling of panel moulds based on deform 3D,” International Journal of Simulation Modelling, vol. 16, no. 2, pp. 343–356, 2017.
  • W. Nie, M. Zheng, S. Xu, Y. Liu, H. Yu, “Design and Optimization of Variable Pitch End Mills Based on Dynamic Balance Accuracy,” 2021.
  • X. X. Wang, X. H. Lu, G. H. Xu, F. C. Wang, “The finite element analysis of the stress and deformation of the micro-milling cutter based on ANSYS,” Applied Mechanics and Materials, vol. 494–495, pp. 345–348, 2014.
  • M. Madajewski, S. Wojciechowski, N. Znojkiewicz, P. Twardowski, “Hybrid numerical-analytical model for force prediction in end milling,” Mechanik, vol. 91, no. 8–9, pp. 757–759, 2018.
  • D. Steinberg, Equation of state and strength properties of selected materials. Lawrence Livermore National Laboratory, 1996.
  • Conical Cutting Tools, “Choosing the Correct Angle End Mill For Your Job,” 2023. https://conicalendmills.com/ordering/selection-guide/helical-angle-selection/ (accessed Feb. 16, 2023).
  • M. Melchiorre, T. Duncan, “The Fundamentals of FEA Meshing for Structural Analysis,” 2021. https://www.ansys.com/blog/fundamentals-of-fea-meshing-for-structural-analysis (accessed Jul. 04, 2022).
  • A. A. Carvalho, “Tips and Tricks for Explicit Simulations,” 2019.
  • Ansys Inc., “Introduction to Ansys Meshing.” Ansys Inc., pp. L5-16, 2011.
  • Ansys Inc., “Mesh Quality And Advanced Topics Ansys Workbench 16.0,” 2015.
  • A. Cambaz, Y. F. Gorgulu, H. Arat, “Analysing fluid-structure interaction with CFD and FEA on a marine double-wall LNG piping system,” Multidisciplinary Scientific Journal of Maritime Research, vol. 36, no. 1, pp. 51–60, 2022.
  • A. Cambaz, Y. F. Görgülü, H. Arat, “Two-Phase Numerical Modelling of a Wet Exhaust System in a Catamaran Motor Yacht Diesel Engine,” European Journal of Science and Technology, vol. 31, no. Supp. 1, pp. 165–170, 2021.
  • Y. F. Görgülü, M. A. Özgür, R. Köse, “NACA 0009 Profilli Bir Kanadin Düşük Bir Reynolds Sayisinda Had Analizi,” Journal of Polytechnic, vol. 0900, no. 3, pp. 1237–1242, 2021.
  • A.L.M.T Corp., “Formula to calculate cutting process,” 2022. https://www.allied-material.co.jp/en/products/diamond/knowledge/cutting_formula.html (accessed Jul. 04, 2022).
  • Helical Solutions, Machining Guidebook. 2016.
  • J. R. Walker, B. Dixon, Machining Fundamentals, 10th ed. The Goodheart-Willcox Company, Inc., 2019.
  • E. Oberg, F. D. Jones, H. L. Horton, H. H. Ryffel, C. J. McCauley, Machinery’s Handbook, 31st ed. Industrial Press, Inc., 2020.
Toplam 36 adet kaynakça vardır.

Ayrıntılar

Birincil Dil İngilizce
Konular Makine Mühendisliği
Bölüm Araştırma Makalesi
Yazarlar

Yasin Furkan Görgülü 0000-0002-1828-2849

Murat Aydın 0000-0002-3015-1868

Erken Görünüm Tarihi 22 Haziran 2023
Yayımlanma Tarihi 30 Haziran 2023
Gönderilme Tarihi 1 Şubat 2023
Kabul Tarihi 6 Mart 2023
Yayımlandığı Sayı Yıl 2023 Cilt: 27 Sayı: 3

Kaynak Göster

APA Görgülü, Y. F., & Aydın, M. (2023). Estimating the Strength and Deformation Properties of the End Milling Process Using Numerical Analysis Methods. Sakarya University Journal of Science, 27(3), 697-707. https://doi.org/10.16984/saufenbilder.1245764
AMA Görgülü YF, Aydın M. Estimating the Strength and Deformation Properties of the End Milling Process Using Numerical Analysis Methods. SAUJS. Haziran 2023;27(3):697-707. doi:10.16984/saufenbilder.1245764
Chicago Görgülü, Yasin Furkan, ve Murat Aydın. “Estimating the Strength and Deformation Properties of the End Milling Process Using Numerical Analysis Methods”. Sakarya University Journal of Science 27, sy. 3 (Haziran 2023): 697-707. https://doi.org/10.16984/saufenbilder.1245764.
EndNote Görgülü YF, Aydın M (01 Haziran 2023) Estimating the Strength and Deformation Properties of the End Milling Process Using Numerical Analysis Methods. Sakarya University Journal of Science 27 3 697–707.
IEEE Y. F. Görgülü ve M. Aydın, “Estimating the Strength and Deformation Properties of the End Milling Process Using Numerical Analysis Methods”, SAUJS, c. 27, sy. 3, ss. 697–707, 2023, doi: 10.16984/saufenbilder.1245764.
ISNAD Görgülü, Yasin Furkan - Aydın, Murat. “Estimating the Strength and Deformation Properties of the End Milling Process Using Numerical Analysis Methods”. Sakarya University Journal of Science 27/3 (Haziran 2023), 697-707. https://doi.org/10.16984/saufenbilder.1245764.
JAMA Görgülü YF, Aydın M. Estimating the Strength and Deformation Properties of the End Milling Process Using Numerical Analysis Methods. SAUJS. 2023;27:697–707.
MLA Görgülü, Yasin Furkan ve Murat Aydın. “Estimating the Strength and Deformation Properties of the End Milling Process Using Numerical Analysis Methods”. Sakarya University Journal of Science, c. 27, sy. 3, 2023, ss. 697-0, doi:10.16984/saufenbilder.1245764.
Vancouver Görgülü YF, Aydın M. Estimating the Strength and Deformation Properties of the End Milling Process Using Numerical Analysis Methods. SAUJS. 2023;27(3):697-70.
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