Numerical investigation of mechanical induced stress during precision end milling hardened tool steel

Research output: Contribution to conferencePaper

Abstract

Hardened tool steels are widely used materials for forming dies, due to their increased strength and hardness. However, their machinability is very poor, due to the high hardness of the material, which leads to high cutting forces and premature failure of the cutting tools. This is also associated with machining induced tensile stresses within the work piece. No full factorial design has been performed when end milling tool steel, due to the high associated costs. Instead of physical experiments, numerical models are commonly used to save cost and time. However, most of the recent research focus was only on 2D FE-Models. 2D model can be used for simulation of some simplified process, however, the results are not sufficient for accurate prediction. Therefore, a 3D FE-model of a precision end milling process with a two-flute ball nose cutter were established in this paper, in order to build a multi cutting edge model. In the FE-Model, a subroutine was implemented to model work piece hardening during the cutting process. The subroutine realised an accurate prediction of the residual stress and cutting forces. In addition, a material removal criterion was developed and implemented. The influence of cutting parameters on cutting force for end milling H13 tool steel was studied, through full factorial numerical simulations, to evaluate the effectiveness of this FEA model. Subsequently, after validation of the FEM model through machining trials, empirical models were developed for predicting cutting forces and residual stress. The cutting parameters evaluated were cutting speed, feed rate and depth of cut. In summary, it was found that the simulation and the experiments had a good agreement on the value and trend of the residual stress. The FEM model can be effectively used to predict residual stress in the machined surface.

Conference

ConferenceInternational Congress on Precision Machining (ICPM 2017)
CountryGreece
CityAthens
Period6/09/179/09/17
Internet address

Fingerprint

Tool steel
Residual stresses
Subroutines
Finite element method
Machining
Hardness
Machinability
Milling (machining)
Cutting tools
Strain hardening
Tensile stress
Costs
Numerical models
Experiments

Keywords

  • FEM
  • milling
  • tool steel
  • residual stress
  • surface integrity

Cite this

Reimer, A., Fitzpatrick, S., Luo, X., & Zhao, J. (Accepted/In press). Numerical investigation of mechanical induced stress during precision end milling hardened tool steel. Paper presented at International Congress on Precision Machining (ICPM 2017), Athens, Greece.
@conference{595e76ffcc3141109402bd03b3416387,
title = "Numerical investigation of mechanical induced stress during precision end milling hardened tool steel",
abstract = "Hardened tool steels are widely used materials for forming dies, due to their increased strength and hardness. However, their machinability is very poor, due to the high hardness of the material, which leads to high cutting forces and premature failure of the cutting tools. This is also associated with machining induced tensile stresses within the work piece. No full factorial design has been performed when end milling tool steel, due to the high associated costs. Instead of physical experiments, numerical models are commonly used to save cost and time. However, most of the recent research focus was only on 2D FE-Models. 2D model can be used for simulation of some simplified process, however, the results are not sufficient for accurate prediction. Therefore, a 3D FE-model of a precision end milling process with a two-flute ball nose cutter were established in this paper, in order to build a multi cutting edge model. In the FE-Model, a subroutine was implemented to model work piece hardening during the cutting process. The subroutine realised an accurate prediction of the residual stress and cutting forces. In addition, a material removal criterion was developed and implemented. The influence of cutting parameters on cutting force for end milling H13 tool steel was studied, through full factorial numerical simulations, to evaluate the effectiveness of this FEA model. Subsequently, after validation of the FEM model through machining trials, empirical models were developed for predicting cutting forces and residual stress. The cutting parameters evaluated were cutting speed, feed rate and depth of cut. In summary, it was found that the simulation and the experiments had a good agreement on the value and trend of the residual stress. The FEM model can be effectively used to predict residual stress in the machined surface.",
keywords = "FEM, milling, tool steel, residual stress, surface integrity",
author = "Andreas Reimer and Stephen Fitzpatrick and Xichun Luo and Jie Zhao",
year = "2017",
month = "5",
day = "2",
language = "English",
note = "International Congress on Precision Machining (ICPM 2017) ; Conference date: 06-09-2017 Through 09-09-2017",
url = "http://www.icpm2017.gr/",

}

Reimer, A, Fitzpatrick, S, Luo, X & Zhao, J 2017, 'Numerical investigation of mechanical induced stress during precision end milling hardened tool steel' Paper presented at International Congress on Precision Machining (ICPM 2017), Athens, Greece, 6/09/17 - 9/09/17, .

Numerical investigation of mechanical induced stress during precision end milling hardened tool steel. / Reimer, Andreas; Fitzpatrick, Stephen; Luo, Xichun; Zhao, Jie.

2017. Paper presented at International Congress on Precision Machining (ICPM 2017), Athens, Greece.

Research output: Contribution to conferencePaper

TY - CONF

T1 - Numerical investigation of mechanical induced stress during precision end milling hardened tool steel

AU - Reimer, Andreas

AU - Fitzpatrick, Stephen

AU - Luo, Xichun

AU - Zhao, Jie

PY - 2017/5/2

Y1 - 2017/5/2

N2 - Hardened tool steels are widely used materials for forming dies, due to their increased strength and hardness. However, their machinability is very poor, due to the high hardness of the material, which leads to high cutting forces and premature failure of the cutting tools. This is also associated with machining induced tensile stresses within the work piece. No full factorial design has been performed when end milling tool steel, due to the high associated costs. Instead of physical experiments, numerical models are commonly used to save cost and time. However, most of the recent research focus was only on 2D FE-Models. 2D model can be used for simulation of some simplified process, however, the results are not sufficient for accurate prediction. Therefore, a 3D FE-model of a precision end milling process with a two-flute ball nose cutter were established in this paper, in order to build a multi cutting edge model. In the FE-Model, a subroutine was implemented to model work piece hardening during the cutting process. The subroutine realised an accurate prediction of the residual stress and cutting forces. In addition, a material removal criterion was developed and implemented. The influence of cutting parameters on cutting force for end milling H13 tool steel was studied, through full factorial numerical simulations, to evaluate the effectiveness of this FEA model. Subsequently, after validation of the FEM model through machining trials, empirical models were developed for predicting cutting forces and residual stress. The cutting parameters evaluated were cutting speed, feed rate and depth of cut. In summary, it was found that the simulation and the experiments had a good agreement on the value and trend of the residual stress. The FEM model can be effectively used to predict residual stress in the machined surface.

AB - Hardened tool steels are widely used materials for forming dies, due to their increased strength and hardness. However, their machinability is very poor, due to the high hardness of the material, which leads to high cutting forces and premature failure of the cutting tools. This is also associated with machining induced tensile stresses within the work piece. No full factorial design has been performed when end milling tool steel, due to the high associated costs. Instead of physical experiments, numerical models are commonly used to save cost and time. However, most of the recent research focus was only on 2D FE-Models. 2D model can be used for simulation of some simplified process, however, the results are not sufficient for accurate prediction. Therefore, a 3D FE-model of a precision end milling process with a two-flute ball nose cutter were established in this paper, in order to build a multi cutting edge model. In the FE-Model, a subroutine was implemented to model work piece hardening during the cutting process. The subroutine realised an accurate prediction of the residual stress and cutting forces. In addition, a material removal criterion was developed and implemented. The influence of cutting parameters on cutting force for end milling H13 tool steel was studied, through full factorial numerical simulations, to evaluate the effectiveness of this FEA model. Subsequently, after validation of the FEM model through machining trials, empirical models were developed for predicting cutting forces and residual stress. The cutting parameters evaluated were cutting speed, feed rate and depth of cut. In summary, it was found that the simulation and the experiments had a good agreement on the value and trend of the residual stress. The FEM model can be effectively used to predict residual stress in the machined surface.

KW - FEM

KW - milling

KW - tool steel

KW - residual stress

KW - surface integrity

UR - http://www.icpm2017.gr/

M3 - Paper

ER -

Reimer A, Fitzpatrick S, Luo X, Zhao J. Numerical investigation of mechanical induced stress during precision end milling hardened tool steel. 2017. Paper presented at International Congress on Precision Machining (ICPM 2017), Athens, Greece.