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18 views30 pages

Mid Presentation

Uploaded by

hamzaaslam07770
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Group Members

 Mohsin 70099258
 Hamza Aslam 70098113
 Chaudhry Usama Waheed 70098690
 Moeez Talat 70099700

Supervisor:
Abdul Rahim
Mid Presentation
Project Title

Effect of cutting speed on chip


thickness and shear angle during
orthogonal cutting of Aluminum
Alloy-A numerical investigation
Contents
 Abstract
 Research Narrative
 Research Novelty
 Research Objectives and Scope
 Literature Survey
 Research Methodology
(a) Description of how research will be conducted.
(b) Theoretical Studies
(c) Results expected and Methods for Analysis
Continue….

 Research Outcomes & Deliverables

 Socio-Economic Benefits of Research

 Research Dissemination Plan

 Research Timetable

 References
Abstract
In this research work, Modelling and simulation of orthogonal metal
cutting of Aluminium 6061-T6 is performed by finite element method
using ABACUS software. Effects of depth of cut, cutting speed and
tool rake face angle on cutting variables such as cutting forces, chip
morphology, temperature and stress distributions are investigated using
the Johnson-Cook and Johnson-Cook damage models. Estimation of
the influence and important process parameters such as cutting speed,
depth of cut, feed and tool rake angle on the cutting forces in tool
geometries design and optimising the cutting conditions for profitable
manufacture of quality machined products. [1]
Research Narrative
 Explicit scheme was preferred over implicit scheme due to
convergence problems of implicit scheme as CPU time
was more to calculate whereas Von-Mises stress (Field
output) and internal energy.[2]
 Our work on abacus software will resolve the problem by
telling the effect of cutting speed on chip thickness and
shear angle during orthogonal cutting of aluminium alloy.
Commercially available software Abaqus/Explicit was
used to simulate a 2D orthogonal model.[3]
Research Novelty

The aim was to predict the chip thickness and


shear angle in the machined component under
various cutting speeds and feed-rates while
keeping the tool geometry and cutting depth
constant. The Boundary conditions were
applied for the both work piece and tool.[4]
Research Objective and Scope

 The objective of the present study is to investigate the chip


morphology in the work-piece (Al-6061-T6) and its sensitivity to
cutting speed and feed rate by using numerical and experimental
methods.
 Commercially available software Abacus/Explicit was used to
simulate a 2D orthogonal model. The work piece was fixed in x-
direction as well as y-direction whereas the tool was allowed to
move in the x-direction only with the prescribed velocity while
keeping the y- direction fixed. The results of chip morphology from
simulation were obtained. [5]
Literature survey
 Scanning Electron Microscope (SEM) studies suggest that chip morphology is
independent of work material microstructure, but varies with tool wear.
Orthogonal cutting tests show that, above a critical speed, segmented chips are
formed by catastrophic localized shear and that chip segmentation spacing may be
reflected in a modulation of the machined surface.
 Segment spacing is a function of depth of cut, rake angle, and surface speed,
approaching a limiting value with speed. Specific cutting energies decrease with
speed, also approaching an asymptote. [6]
 A simple mechanical model gives reasonable predictions of segment spacing
along the original surface, although a full thermo-plastic model will be required to
account for other aspects of the chip formation process. modelling and simulation
of orthogonal metal cutting of Aluminium 6061-T6 is also performed by finite
element method using ANSYS 19.2 software.
Research Methodology
(a) Description of how research will be conducted
 This research will performed on abacus software.
In this study, a fully coupled thermal-mechanical
FE model in ABAQUS/Explicit was created to
analyse the Al6061-T6 chip morphology at cutting
speeds between 250 and 1000 m/min and feed rates
between 0.1 and 0.4 mm/rev. [7]
(b) Theoretical Studies

 Cutting speed is generally defined as the relative velocity between


the surface of the workpiece and the cutting tool. Some experts also
define it as how fast the workpiece moves past the cutting edge of
the tool. Machinists measure it in meters per minute (m/min) or feet
per minute (ft/min). [8]
Continue….

 Feed rate is the distance which the cutting tool during one spindle
revolution. It is also defined as the velocity at which the cutter is
advanced against the work piece. It is measured in milli-meters per
revolution mmpr for turning and boring processes.[8]
 The depth of cut (t) is the perpendicular distance measured from the
machined surface to the uncut surface of the workpiece.[8]
Continue….

Chip:
 When performing a manufacturing process on a work piece, chips
are often created as a byproduct. Using a lathe to cut a metal work
piece, for instance, will create chips in the form of metal shavings.
1. Continuous chip
2. Discontinuous chip
3. Continuous chip with built-up edge
4. Serrated chip
Continue….
Shear Angle:
The angle at which the chip will separate from the work material
during metal cutting is called the shear angle.
The shear angle is of fundamental importance in chip formation. The
smaller the shear angle the larger the strain, the machining forces, and
the power requirements.
Continue….
 The orthogonal cutting process is a two-dimensional cutting analysis
in which the tool's cutting edge is perpendicular to the direction of
cutting speed. The chip is formed due to shear deformation in the
shear plane.
 This allows us to deal with stresses and strains that act in a plane
(c) Results expected and Methods for Analysis
Research Outcomes & Deliverables

 Abacus will helpful to simulate the predicted chip


morphology by using a aluminium 6061 model. Under the
selected range of cutting velocities and feed-rates, the chip
thickness decreased with the increase of cutting speed and
increased with the increase of feed rate. Shear angles were
also found to be sensitive to cutting parameters and
increased with the increase of cutting speed and feed rate.
[9]
Socio economic benefits of research

 Cheaper

 Easy to use

 Accuracy

 This technique (ABAQUS) measure different chip locations and extremely small

values of chip thickness in microns.


Research Dissemination Plan

 Increasing feed was helpful to form a curl chip. A


high cutting speed was helpful to form ribbon chip
relatively.
 High-speed orthogonal cutting method can obtain
important chip formation parameters in aluminum
alloy 6061-T6 and avoid the cutting speed
limitation in quick- stop test, leading to a lower
experiment difficulty. [10]
Research Timetable
References
 [1] Adedeji. A. Kasali, Nurudeen. A. Raji, Fadipe.O. Lukman,
Aderibigbe.O. Michael. Lagos State University,
P.M.B.1087 Apapa, Lagos
 [2] https://
www.researchgate.net/publication/303688007_A_numerical_inves
tigation_and_experimental_validation_on_chip_morphology_of_Al
uminum_Alloy_6061_during_orthogonal_machining
 [3]
https://
www.researchgate.net/publication/303688007_A_numerical_investig
ation_and_experimental_validation_on_chip_morphology_of_Aluminu
m_Alloy_6061_during_orthogonal_machining
Continue….

 [4]
https://www.researchgate.net/publication/303688007_A_numerical_i
nvestigation_and_experimental_validation_on_chip_morphology_of_
Aluminum_Alloy_6061_during_orthogonal_machining
 [5]
https://www.researchgate.net/publication/303688007_A_numerical_i
nvestigation_and_experimental_validation_on_chip_morphology_of_
Aluminum_Alloy_6061_during_orthogonal_machining
 [6]
Davies, Matthew A., Y. Chou, and Christopher J. Evans. "On chip
morphology, tool wear and cutting mechanics in finish hard
turning." CIRP annals 45, no. 1 (1996): 77-82.
Continue….

 [7]
https://
www.researchgate.net/publication/303688007_A_numerical_investig
ation_and_experimental_validation_on_chip_morphology_of_Aluminu
m_Alloy_6061_during_orthogonal_machining
 [8]
https://www.theengineerspost.com/lathe-machine-formula/
 [9]
https://www.researchgate.net/publication/303688007_A_numerical_i
nvestigation_and_experimental_validation_on_chip_morphology_of_
Aluminum_Alloy_6061_during_orthogonal_machining
Continue….

 [10]
https://
www.researchgate.net/publication/271795020_Research_on_chip_fo
rmation_parameters_of_aluminum_alloy_6061-T6_based_on_high-sp
eed_orthogonal_cutting_model

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