Development of fem model for high speed machining using small ball end milling processes

Development of fem model for high speed machining using small ball end milling processes

This thesis describes the development of 2D and 3D finite element (FE) models for the high speed machining on laser sintered material, LSMEp9. The work employed finite element method (FEM) with the application of Updated Lagrangian Formulation. Mild steel, AISI1O5S was used as a comparison. Finite e...

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Main Author: Ahmad Shahir, Jamaludin
Format: Thesis
Language:English
Published: 2013
Subjects:
TJ Mechanical engineering and machinery
Online Access:http://umpir.ump.edu.my/id/eprint/9008/
http://umpir.ump.edu.my/id/eprint/9008/
http://umpir.ump.edu.my/id/eprint/9008/1/AHMAD%20SHAHRIR%20BIN%20JAMALUDIN.PDF
id ump-9008
recordtype eprints
spelling ump-90082015-11-11T03:05:02Z http://umpir.ump.edu.my/id/eprint/9008/ Development of fem model for high speed machining using small ball end milling processes Ahmad Shahir, Jamaludin TJ Mechanical engineering and machinery This thesis describes the development of 2D and 3D finite element (FE) models for the high speed machining on laser sintered material, LSMEp9. The work employed finite element method (FEM) with the application of Updated Lagrangian Formulation. Mild steel, AISI1O5S was used as a comparison. Finite element simulation results of cutting force show errors of 10%, compared with experimental results when shear friction factor, m 0.8 was applied. The cutting force shows increasing values when the radial depth of cut increases for both types of materials due to chip removal rate increases. However, the cutting force decreases when the cutting speed increases due to the decreases of chip thickness and less contact time between tool and chip. The cutting temperature increases when the cutting speed increases due to increasing in 'cutting 'energy. Cutting force for laser sintered material, LSMEp9 is lower than mild steel, AISI1055 due to its lower young modulus while its cutting temperature is higher than AISI1055 due to its lower thermal conductivity. Extended studies were done for ball end mill with the diameter equal or less than 2mm. The predicted cutting temperature for ball end mills with diameter 2 mm and less shows big error compared with the experimental results due to the size effect of the ball end mill was neglected in the simulation. The heat capacity of the small size of the ball 'end mill is considerably low, thus the end mill could suffer excessive increases of cutting temperature. The large ratio of feed rate per tool radius (>0.1) could lead to increases of tool wear rate, thus worsen the heat capacity of small ball end mill. The study on effect of tool wear evolution during machining on the cutting temperature was done. In the study, cutting temperature increases when flank wear of the tool increases, while prolong machining increased the cutting temperature gradient critically. Increasing temperature during machining could affect the surface integrity of the workpiece and cutting tool, lowered the tool life and quality of the manufactured products. 2013 Thesis NonPeerReviewed application/pdf en http://umpir.ump.edu.my/id/eprint/9008/1/AHMAD%20SHAHRIR%20BIN%20JAMALUDIN.PDF Ahmad Shahir, Jamaludin (2013) Development of fem model for high speed machining using small ball end milling processes. Masters thesis, Universiti Malaysia Sarawak. http://iportal.ump.edu.my/lib/item?id=chamo:83702&theme=UMP2
repository_type Digital Repository
institution_category Local University
institution Universiti Malaysia Pahang
building UMP Institutional Repository
collection Online Access
language English
topic TJ Mechanical engineering and machinery
spellingShingle TJ Mechanical engineering and machinery
Ahmad Shahir, Jamaludin
Development of fem model for high speed machining using small ball end milling processes
description This thesis describes the development of 2D and 3D finite element (FE) models for the high speed machining on laser sintered material, LSMEp9. The work employed finite element method (FEM) with the application of Updated Lagrangian Formulation. Mild steel, AISI1O5S was used as a comparison. Finite element simulation results of cutting force show errors of 10%, compared with experimental results when shear friction factor, m 0.8 was applied. The cutting force shows increasing values when the radial depth of cut increases for both types of materials due to chip removal rate increases. However, the cutting force decreases when the cutting speed increases due to the decreases of chip thickness and less contact time between tool and chip. The cutting temperature increases when the cutting speed increases due to increasing in 'cutting 'energy. Cutting force for laser sintered material, LSMEp9 is lower than mild steel, AISI1055 due to its lower young modulus while its cutting temperature is higher than AISI1055 due to its lower thermal conductivity. Extended studies were done for ball end mill with the diameter equal or less than 2mm. The predicted cutting temperature for ball end mills with diameter 2 mm and less shows big error compared with the experimental results due to the size effect of the ball end mill was neglected in the simulation. The heat capacity of the small size of the ball 'end mill is considerably low, thus the end mill could suffer excessive increases of cutting temperature. The large ratio of feed rate per tool radius (>0.1) could lead to increases of tool wear rate, thus worsen the heat capacity of small ball end mill. The study on effect of tool wear evolution during machining on the cutting temperature was done. In the study, cutting temperature increases when flank wear of the tool increases, while prolong machining increased the cutting temperature gradient critically. Increasing temperature during machining could affect the surface integrity of the workpiece and cutting tool, lowered the tool life and quality of the manufactured products.
format Thesis
author Ahmad Shahir, Jamaludin
author_facet Ahmad Shahir, Jamaludin
author_sort Ahmad Shahir, Jamaludin
title Development of fem model for high speed machining using small ball end milling processes
title_short Development of fem model for high speed machining using small ball end milling processes
title_full Development of fem model for high speed machining using small ball end milling processes
title_fullStr Development of fem model for high speed machining using small ball end milling processes
title_full_unstemmed Development of fem model for high speed machining using small ball end milling processes
title_sort development of fem model for high speed machining using small ball end milling processes
publishDate 2013
url http://umpir.ump.edu.my/id/eprint/9008/
http://umpir.ump.edu.my/id/eprint/9008/
http://umpir.ump.edu.my/id/eprint/9008/1/AHMAD%20SHAHRIR%20BIN%20JAMALUDIN.PDF
first_indexed 2023-09-18T22:07:06Z
last_indexed 2023-09-18T22:07:06Z
_version_ 1777414781373775872

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