Three-dimensional finite element modeling of rough to finish down-cut milling of an aluminum alloy

Muhammad Asad, Tarek Mabrouki, Asif A. Memon, Syed Mushtaq A Shah, Muhammad A. Khan

Research output: Contribution to journalArticle

9 Citations (Scopus)

Abstract

This contribution deals with a computational investigation highlighting the effects of cutting speed and depth of cut on chip morphology and surface finish for down-cut milling case. The global aim concerns the comprehension of multiphysical phenomena accompanying chip formation in rough, semifinish, and finish cutting operations, exploiting a three-dimensional finite element model. Numerical work has been performed in two phases. In the first phase, a three-dimensional model for rough cut operation has been validated with the experimental results, including chip morphology and cutting force evolution for an aerospace grade aluminum alloy A2024-T351. In the second phase, the model has been extended to semifinish and finish three-dimensional cutting operations. The numerical findings show that as depth of cut decreases (toward finish cutting), spatial displacement of workpiece nodes along the depth of cut increases. This represents an increase/extension in the percentage of volume undergoing shear deformation, resulting in higher dissipation of inelastic energy, hence contributing to size effect in finish cutting operation. The results also depict that material strain rate hardening enhances the material strength at higher cutting speeds. These material strengthening phenomena help to generate a smooth continuous chip morphology and better surface texture in high-speed finishing operations. The study highlights the significance of three-dimensional numerical modeling to better understand the chip formation process in semifinish and finish machining operations, regardless of the immense effort in computational time.

Original languageEnglish
Pages (from-to)75-83
Number of pages9
JournalProceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture
Volume227
Issue number1
DOIs
Publication statusPublished - Jan 2013
Externally publishedYes

Fingerprint

Aluminum alloys
Shear deformation
Hardening
Strain rate
Machining
Textures

Keywords

  • A2024-T351
  • chip evolution
  • down-cut milling
  • finish machining
  • Three-dimensional finite element modeling

ASJC Scopus subject areas

  • Industrial and Manufacturing Engineering
  • Mechanical Engineering

Cite this

Three-dimensional finite element modeling of rough to finish down-cut milling of an aluminum alloy. / Asad, Muhammad; Mabrouki, Tarek; Memon, Asif A.; Shah, Syed Mushtaq A; Khan, Muhammad A.

In: Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, Vol. 227, No. 1, 01.2013, p. 75-83.

Research output: Contribution to journalArticle

Asad, Muhammad ; Mabrouki, Tarek ; Memon, Asif A. ; Shah, Syed Mushtaq A ; Khan, Muhammad A. / Three-dimensional finite element modeling of rough to finish down-cut milling of an aluminum alloy. In: Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture. 2013 ; Vol. 227, No. 1. pp. 75-83.
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