WWW.THESIS.DISLIB.INFO
FREE ELECTRONIC LIBRARY - Online materials, documents
 
<< HOME
CONTACTS



«International Journal of Computational Engineering Research||Vol, 03||Issue, 4|| Structural Analysis of a Milling Cutter Using FEA Chittibomma. ...»

International Journal of Computational Engineering Research||Vol, 03||Issue, 4||

Structural Analysis of a Milling Cutter Using FEA

Chittibomma. Tirumalaneelam1, Tippa Bhimasankara Rao2

PG Student, Department Of Mechanical Engineering, Nimra Institute Of Science And Technology

HOD, Department Of Mechanical Engineering, Nimra Institute Of Science And Technology, Vijayawada, AP,

INDIA

Abstract:

Milling is a process of producing flat and complex shapes with the use of multi-tooth cutting tool, which is called a milling cutter and the cutting edges are called teeth. The axis of rotation of the cutting tool is perpendicular to the direction of feed, either parallel or perpendicular to the machined surface. The machine tool that traditionally performs this operation is a milling machine. Milling is an interrupted cutting operation: the teeth of the milling cutter enter and exit the work during each revolution. This interrupted cutting action subjects the teeth to a cycle of impact force and thermal shock on every rotation. The tool material and cutter geometry must be designed to withstand these conditions. Cutting fluids are essential for most milling operations.In this Paper the design aspects of milling cutter is analyzed. The objective considered is the design and modeling of milling cutter and to analyse various stress components acting on it. Various designing strategies are considered to design the effective milling cutter like outer diameter, inner diameter, radius, teeth angle etc.The design and analysis is carried out using the softwares like CATIA V5 and ANSYS.

Keywords: ANSYS, CATIA, cutting fluids, cutting edges, High Speed Steel, Milling Speed, machined surfaces, surface milling cutter.

I. INTRODUCTION Milling, for example, has its own particularities, such as variation on the unreformed chip thickness (h), interrupted cuts, etc. Models developed for turning and adapted to milling, working with average chip thickness, can yield reasonable results in terms of force. There are operations, however, where a more accurate result is needed and then, the discrepancies may become unacceptable. That is the case with high speed milling, which uses very low chip thickness. In this case, the cutting edge radius almost equals the unreformed chip thickness and the rake angle tends to be highly negative. The material seems to be removed like in abrasive processes (Shaw 1996). Additionally, the main parameters describing the models are a function of other ones related to the tool (material, geometry, coating, etc.) and the machine (rigidity, speed, position control, etc.). In order to investigate the end milling process in some cutting conditions, at any particular combination tool-machine-work piece, a simple and fast method is needed to find the main parameters of the classical existing models and study some new ones. Milling is a process of producing flat and complex shapes with the use of multi-tooth cutting tool, which is called a milling cutter and the cutting edges are called teeth. The axis of rotation of the cutting tool is perpendicular to the direction of feed, either parallel or perpendicular to the machined surface. The machine tool that traditionally performs this operation is a milling machine. Milling is an interrupted cutting operation: the teeth of the milling cutter enter and exit the work during each revolution. This interrupted cutting action subjects the teeth to a cycle of impact force and thermal shock on every rotation. The tool material and cutter geometry must be designed to withstand these conditions. Cutting fluids are essential for most milling operations.

–  –  –

1.1 Types of milling There are two basic types of milling, are as follows  Down (climb) milling: It is type of milling in which the cutter rotation is in the same direction as the motion of the work piece being fed. In down milling, the cutting force is directed into the work table, which allows thinner work parts to be machined. Better surface finish is obtained but the stress load on the teeth is abrupt, which may damage the cutter. In conventional milling, friction and rubbing occur as the insert enters into the cut, resulting in chip welding and heat dissipation into the insert and work piece. Resultant forces in conventional milling are against the direction of the feed. Work-hardening is also likely to occur.

Fig 2: Climb Milling Fig 3: Conventional Milling

 Up (conventional) milling: It is the type of milling in which the work piece is moving towards the cutter, opposing the cutter direction of rotation. In up milling, the cutting force tends to lift the work piece. The work conditions for the cutter are more favorable. Because the cutter does not start to cut when it makes contact (cutting at zero cut is impossible), the surface has a natural waviness. The insert enters the work piece material with some chip load and produces a chip that thins as it exits the cut. This reduces the heat by dissipating it into the chip. Work-hardening is minimized. Climb milling is preferred over conventional milling in most situations.

1.2 Milling of complex surfaces Milling is one of the few machining operations, which are capable of machining complex two and three-dimensional surfaces, typical for dies, molds, cams, etc. Complex surfaces can be machined either by means of the cutter path (profile milling and surface contouring), or the cutter shape (form milling).





 Form milling: In form milling, the cutting edges of the peripheral cutter (called form cutter) have a special profile that is imparted to the work piece. Cutters with various profiles are available to cut different twodimensional surfaces. One important application of form milling is in gear manufacturing.

 Profile milling: In profile milling, the conventional end mill is used to cut the outside or inside periphery of a flat part. The end mill works with its peripheral teeth and is fed along a curvilinear path equidistant from the surface profile.

 Surface contouring: The end mill, which is used in surface contouring has a hemispherical end and is called ball-end mill. The ball-end mill is fed back and forth across the work piece along a curvilinear path at close intervals to produce complex three-dimensional surfaces. Similar to profile milling, surface contouring require relatively simple cutting tool but advanced, usually computer-controlled feed control system.

II. Classification of milling cutters according to their design  HSS cutters: Many cutters like end mills, slitting cutters, slab cutters, angular cutters, form cutters, etc., are made from high-speed steel (HSS).

 Brazed cutters: Very limited numbers of cutters (mainly face mills) are made with brazed carbide inserts.

This design is largely replaced by mechanically attached cutters.

 Mechanically attached cutters: The vast majority of cutters are in this category. Carbide inserts are either clamped or pin locked to the body of the milling cutter.

III. Geometry of milling cutter The milling cutter is a multiple point cutting tool. The cutting edge may be straight or in the form of various contours that are to be reproduced upon the work piece. The relative motion between the work piece and the cutter may be either axial or normal to the tool axis. In some cases a combination of the two motions is used.

For example, form-generating milling cutters involve a combination of linear travel and rotary motion. The figure below shows the various angles and geometry of a milling cutter.

–  –  –

V. ANALYSIS OF MILLING CUTTER

The basic steps for performing analysis are listed below:

 Create the model geometry and mesh  Identify the contact pairs  Designate contact and target surfaces  Define the target surface  Define the contact surface  Set the element KEYOPTS and real constants  Define/control the motion of the target surface (rigid-to-flexible only)  Apply necessary boundary conditions  Define solution options and load steps  Solve the contact problem  Review the results VI. RESULTS & DISCUSSION  CASE 1: Analysis of High Speed Steel Milling cutter for W=10000 N

–  –  –

VII. Conclusion

In this study the design and analysis is carried out for two different cutter materials and they are High Speed Steel and Tungsten Carbide. In this analysis the loads acting on the cutter and speed is varied and the results obtained are compared. Finally the design and analysis is carried out using the software‟s CATIA V5, ANSYS.It could even be ventured that this approach can be used to design any complex mechanical component or system. Specifically for the cutter design, it produced the cutting variables that yield the minimum cost of manufacturing. The different design activities, such as design, solid modelling, and finite element analysis, have been integrated. As is evident, approach presented in this paper is flexible and easy to use.

Page 104 www.ijceronline.com ||April||2013|| Structural Analysis Of A Milling Cutter Using Fea...

REFERENCES

Mr. John L. Yang & Dr. Joseph C. Chen; „A Systematic Approach for Identifying Optimum Surface Roughness Performance in [1].

End-Milling Operations‟. Journal of Industrial Technology, Volume 17, Number 2-February 2001 to April 2001.

Abdel Badie Sharkawy, “Prediction of Surface Roughness in End Milling Process Using [2].

Intelligent Systems”: A Comparative StudyHindawi Publishing Corporation Applied Computational Intelligence and Soft [3].

Computing Volume 2011, Article ID 183764, 18 pages.

Abbas Fadhel Ibraheem, Saad Kareem Shather & Kasim A. Khalaf, “Prediction of Cutting Forces by using Machine Parameters in [4].

end Milling Process”, Eng.&Tech. Vol.26.No.11, 2008.

S. Abainia, M. Bey, N. Moussaoui and S. Gouasmia.” Prediction of Milling Forces by Integrating a Geometric and a Mechanistic [5].

Model”, Proceedings of the World Congress on Engineering 2012 Vol III WCE 2012, July 4 - 6, 2012, London, U.K.

Md. Anayet u patwari, a.k.m. nurul amin, waleed f. Faris, „prediction of tangential cutting force in end milling of Medium carbon [6].

steel by coupling design of experiment and Response surface methodology‟. Journal of mechanical engineering, vol. Me 40, no. 2, December 2009 Transaction of the mech. Eng. Div., the institution of engineers, Bangladesh.

Smaoui, M.; Bouaziz,z. &Zghal,A., „Simulation of cutting forces for complex surfaces in Ball-End milling‟, Int j simul model [7].

7(2008) 2,93-105.

F. CUS, U. ZUPERL and M. MILFELNER, “Dynamic Neural Network Approach for Tool Cutting Force Modelling of End Milling [8].

Operations. Journal of Material Processing and Technology 95 pp. 30 – 39.

[9]. Mohan, L. V. Profile Corrections for relieving tool for form relieved milling cutters. Proceedings of the 12th All India Machine Tool Design and Research Conference 1986, Dec. l&12, pp. 2255228.

[10]. Davies, R. Bonding cemented carbide milling cutter inserts. Proceedings of Materials Selection & Design, London, July, 1985..

[11]. Granger, C. Never too old to pick up milling tips. Machinery Prod, Eng. 1991,149(3797), 1617, 19-20 [12]. Agullo-Bathe, J., Cardona-Foix, S. and Vinas-Sanz, C. On the design of milling cutters or grinding wheels for twist drill manufacture: A CAD approach. Proceedings of the 25 th International Machine Tool Design and Research Conference, April 22-24, 1985, pp. 315-320.



Similar works:

«Informal, Non‐standard, Precarious: concepts and measurements in  France and EU; implications for international comparative  evaluations.  Brief note for the WIEGO meeting, “Measuring Informal Employment in Developed Countries”, Boston, 31 October-1st November 2008 and revised January 2009 François Michon (CNRS et Université de Paris 1,  Centre d’Études de la Sorbonne) 1  1)  Are  concepts  of  non‐standard  arrangements  and  informal ...»

«Protocol Treatment of primary irresectable, locally advanced pancreatic cancer. The S-LAPC trial Study secretariat: Department of Surgical Gastroenterology, Gastrocentrum, Karolinska University Hospital, Huddinge, Stockholm Sweden Principal investigator: John Blomberg MD, PhD, Department of Surgical Gastroenterology, Gastrocentrum, Karolinska University Hospital, Huddinge, 141 86 Stockholm Sweden e-mail: john.blomberg@karolinska.se Background: Due to diffuse symptoms pancreatic cancer is...»

«PLANT PIGMENTS AND PHOTOSYNTHESIS STANDARDS • 3.2.10A, 3.2.10B, 3.2.12A, 3.2.12B • 3.3.10.B, 3.3.12B Westminster College INTRODUCTION Isolation of Plant Pigments Paper chromatography is a technique that can be used to separate a complex mixture of molecules. In green plants, there is a mixture of four basic pigments found in their leaves. These pigments are shown in Table 1. Pigment Color Function Capture light energy and transfer it to Carotene Red, orange, yellow chlorophyll a; protect...»

«World Review of Science, Technology and Sustainable development, Vol. x, No. x, xxxx 1 Prediction markets: an information aggregation perspective to the forecasting problem Georgios Tziralis* Sector of Industrial Management and Operational Research Mechanical Engineering School National Technical University of Athens 9 Iroon Polytechnioy Street, 15780 Athens, Greece E-mail: gtzi@central.ntua.gr *Corresponding author Ilias Tatsiopoulos Sector of Industrial Management and Operational Research...»

«Excerpt from UNBLOCK THE POWER OF YOUR SALESFORCE! W.A.Woehr, D.Legat ISBN 3-7083-0082-3 (German: ISBN 3-7083-0166-8) Order on-line at www.delta-institute.com – or at your favorite bookshop © Copyright Delta-Institute S.A. 12 chemin de Pomone CH 1228 Plan les Ouates Tel. +41 (22) 885-02-75 Fax +41 (22) 885-02-76 mail@delta-institute.com www.delta-institute.com All rights reserved. No part of this material may be reproduced in any form or by any means, electronic, mechanical, photocopying,...»

«Article Empirical Study of Employment Arrangements and Precariousness in Australia Amber M. Louie, Aleck S. Ostry, Michael Quinlan, Tessa Keegel, Jean Shoveller et Anthony D. LaMontagne Relations industrielles / Industrial Relations, vol. 61, n° 3, 2006, p. 465-489.Pour citer cet article, utiliser l'information suivante : URI: http://id.erudit.org/iderudit/014186ar DOI: 10.7202/014186ar Note : les règles d'écriture des références bibliographiques peuvent varier selon les différents...»

«Master Thesis of Science Single Blade Installation for Large Wind Turbines in Extreme Wind Conditions A Quasi-Steady Aeroelastic Study in High Wind Speeds under Different Inflow Angles L. Kuijken February 2, 2015 European Wind Energy Master EWEMRotordesign Track Single Blade Installation for Large Wind Turbines in Extreme Wind Conditions A Quasi-Steady Aeroelastic Study in High Wind Speeds under Di↵erent Inflow Angles Master of Science Thesis For obtaining the degree of Master of Science in...»

«Working Report 2014-35 Geological 3D Model of the Investigation Niche in ONKALO, Olkiluoto, Southwestern Finland Noora Koittola Posiva Oy July 2014 Working Reports contain information on work in progress or pending completion.   ABSTRACT The main goal of this Master of Science Thesis was to create a geological 3D-model of the investigation niche 3 and its surroundings. The model were created for the needs of the rock mechanical back analysis. This study is a part of Posiva's regional studies...»

«PRT Vehicle Architecture and Control in Masdar City Menno de Graaf Product Development, Cargotec ACT, Proostwetering 26, 3543 AE Utrecht, The Netherlands; phone +31 30 241 54 22; menno@advancedcargo.eu Abstract The carbon neutral, zero emission Masdar city incorporates Personal Rapid Transit (PRT), the solution that provides on-demand, private transit directly from origin to destination. The city will feature a network of guide-ways with a large station density ensuring short walking distances...»

«D Journal of Modern Accounting and Auditing, March 2016, Vol. 12, No. 3, 147-155 doi: 10.17265/1548-6583/2016.03.002 DAVID PUBLISHING Relationship Between Working Capital Management and Profitability in Turkey Industrial Listed Companies Necdet Saglam Aziz Kagitci, Semih Buyukipekci Anadolu University, Eskisehir, Turkey Selcuk University, Selcuk, Turkey The present study investigated the effect of working capital management component on corporate profitability. A sample of 106 firms listed on...»

«EUROPEAN REAL ESTATE SOCIETY 22nd ANNUAL CONFERENCE 24-27 JUNE 2015 TAŞKIŞLA I İSTANBUL Conference Programme ITU Faculty of Architecture ITU Urban and Environmental Planning and Research Center ITU Real Estate Development Master’s Program 22nd Annual European Real Estate Society Conference ERES 2015 Istanbul Conference Programme 24–27 June 2015 Istanbul, Turkey Organised by Istanbul Technical University Faculty of Architecture | Urban and Enviromental Planning and Research Center | Real...»

«Preparation and Characterization of Noble Metal Single Crystal Electrode Surfaces Ludwig A. Kibler Department of Electrochemistry University of Ulm 89069 Ulm, Germany http://www.uni-ulm.de/echem e-mail: ludwig.kibler@chemie.uni-ulm.de © 2003 by International Society of Electrochemistry. All Rights Reserved. Copyright No part of this booklet may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, microfilming, and recording, or by any...»





 
<<  HOME   |    CONTACTS
2017 www.thesis.dislib.info - Online materials, documents

Materials of this site are available for review, all rights belong to their respective owners.
If you do not agree with the fact that your material is placed on this site, please, email us, we will within 1-2 business days delete him.