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

Yasin Furkan Görgülü; Murat Aydın

Article Details

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

Authors:

Yasin Furkan Görgülü | Murat Aydın

Publisher:

Sakarya University

Main Topics:

Mechanical Engineering

Journal:

Sakarya University Journal of Science Vol.27 Issue 3, pp.697-707

Document Type:

Article

Publication Date:

6/2023

Document Language:

English

Document ID (Org No.):

2001292208

pISSN:

2147-835X

Keywords:

Abstract:

 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 mms. 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 mmmm. Also, the stress values were obtained as 78.23, 76.83, and 77.99 MPa.

 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 mms. 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 mmmm. Also, the stress values were obtained as 78.23, 76.83, and 77.99 MPa.

 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 mms. 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 mmmm. Also, the stress values were obtained as 78.23, 76.83, and 77.99 MPa.

 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 mms. 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 mmmm. Also, the stress values were obtained as 78.23, 76.83, and 77.99 MPa.

Article Details

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

Authors:

Yasin Furkan Görgülü | Murat Aydın

Publisher:

Sakarya University

Main Topics:

Mechanical Engineering

Journal:

Sakarya University Journal of Science Vol.27 Issue 3, pp.697-707

Document Type:

Article

Publication Date:

6/2023

Document Language:

English

Document ID (Org No.):

2001292208

pISSN:

2147-835X

Ansys

deformation

end mill

explicit dynamics

stress and strain.Ansys

deformation

end mill

explicit dynamics

stress and strain

Issues

Article Details

Authors: Yasin Furkan Görgülü | Murat Aydın

Publisher: Sakarya University

Main Topics: Mechanical Engineering

Journal: Sakarya University Journal of Science Vol.27 Issue 3, pp.697-707

Document Type: Article

Publication Date: 6/2023

Document Language: English

Document ID (Org No.): 2001292208

pISSN: 2147-835X

Issues

Authors:

Yasin Furkan Görgülü | Murat Aydın

Publisher:

Sakarya University

Main Topics:

Mechanical Engineering

Journal:

Sakarya University Journal of Science Vol.27 Issue 3, pp.697-707

Document Type:

Article

Publication Date:

6/2023

Document Language:

English

Document ID (Org No.):

2001292208

pISSN:

2147-835X