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12th–14th, 2014,
IIT Guwahati, Assam, India
Abstract
This paper presents the modeling and simulation of deformation of thin-wall section using finite element method
(FEM). A 3D non-linear numerical model was developed by employing Johnson-Cook material constitutive
model for aluminum 7075-T6 alloy. Johnson-cook damage law was adopted to account for damage initiation
and chip formation during cutting tool penetration into the work material. The deformation of thin-walled part
under the action of cutting forces during milling operation was studied for a set of process conditions and the
preliminary results are discussed.
Keywords: Thin-wall machining, numerical simulation, deformation, aluminum 7075-T6
1 Introduction
Aerospace industry needs monolithic thin-wall Ratchev et al. (2003) (2004) developed a flexible
components to manufacture the sections of aircraft cutting force model and investigated the deflection of
fuselage, wings, aircraft door frame, and engine the low rigidity parts under the action of the
blades. Monolithic parts are machined from a single calculated cutting forces. In the similar way, Tang and
block of workpiece to their final shape. Monolithic Liu (2008) studied the deformations of thin-walled
parts are preferred over the traditional riveted-welded plate under the action of static end milling forces.
parts due to the high set-up cost and long time of
production associated with the later [Campa et al.
(2007)]. During the machining of thin-wall parts,
their sections deform under the action of cutting
forces. This leads to geometrical errors which in turn
influence the quality and accuracy of final product.
The geometrical error produced during machining of a
thin-wall part is shown in figure 1. The material
ABCD needs to be cut away ideally. However, under
the action of machining forces, the low rigidity thin-
wall structure deflects, which results in cutting away
of material A’BCD. When the cutter moves away
from the milled surface, the wall elastically recovers,
and material C’CD remains uncut. This was a
common problem observed in the machining of thin-
wall components. This causes the shape of the wall to
be thicker atthe top and thinner atits bottom.
Researchers proposed that the machining errors can
be minimized either by trial and error approach or by
repetitive feeding techniques. However this may lead
in longer production time and higher costs. Figure 1 Error in thin-wall machining
Finite element modeling can be used to simulate
machining of thin-wall parts to predict the deflection Tanase et al. (2010) analyzed the deformation
and deformation of thin-walls. Literature reports during milling thin-walled parts. The cutting forces
research on various aspects of thin-wall machining were determined separately based on the cutting
such as deflection, deformation, machining mechanics power measured during experiments.Few attempts
and dynamics, error prediction and control. have been reported on 3D finite element modeling of
milling process. Pittalà and Monno (2010) simulated
the face milling of aluminum alloy. Soo et al. (2010)
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3D finite element modeling of thin-wall machining of aluminum 7075-T6 alloy
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5th International & 26th All India Manufacturing Technology, Design and Research Conference (AIMTDR 2014) December 12th–14th, 2014,
IIT Guwahati, Assam, India
Table1 Cutting tool parameters [Sekiguchi et al. developed by Johnson & Cook (1985) has been
(2004)] employed. This model uses a damage parameter
Dwhich isdefined as the sum of the ratio of the
Tool material HSS increments in the equivalent plastic strain to the
Tool diameter (mm) 8 fracture strain as given in equation 2.
Tool clearance angle (⁰) 15 The fracture strain is of the form as given in
equation 3.
Number of flutes 4
•
P ε
ε f = D1 + D2 exp D3 _ 1 + D4 ln •
σ
2.2 Material properties and material constitutive
equation ε0 (3)
Aluminum alloy 7075-T6 (A7075-T6), an T - Troom
1 + D5
aerospace material was used in the present study. It is Tmelt - Troom
an aluminum–zinc alloy which is a primary alloy used
in airframe structural applications. This alloy is used
in upper wing skins of aircrafts where high strength is Where, - are the damage constants, P is the
required [Starke and Staley (1996)]. hydrostatic pressure and is equivalent flow stress.
Constitutive equation is an equation which Constants of the J-C failure model for AA7075-T6
describes the thermo-mechanical properties of a determined by Brar et al. 2009 are tabulated in table 4.
material undergoing deformation.Johnson–Cook (J-C)
constitutive equation is used to characterize the Table 3 Workpiece material properties
material behavior of the workpiece. It provides the [Matweb.com (2014)]
description of material behavior undergoing large
Density, ρ 2810
strains, temperature-dependent visco-plasticity and
high strain rates. The model is represented by Elastic modulus, E (GPa) 71.7
equivalent flow stress σ as stated in the equation 1.
Poisson ratio, ν 0.33
• m
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3D finite element modeling of thin-wall machining of aluminum 7075-T6 alloy
can be divided into two regions namely the sliding the elements. This is computed by using the equation
region and the sticking region. Sticking friction is 6.
observed occurring very near the cutting edge in
contact with the workpiece and the sliding friction lmin
∆t ≈ (6)
occurring far away from the contact area. The sliding cd
region obeys the Coulomb friction law. In the sticking
region, the shear stress τ is equal to the critical ABAQUSTM explicit software was used to carry out
frictional stress . The modified coulomb law is the simulation work. Total simulation time taken was
defined by the equations (4) (5). 100hrs with a 3.4GHz, 4GB RAM processor.
τ = τ criti when µσ > τ criti (Sticking region) (4) Table 5 Cutting condition during machining
τ = µσ when µσ > τ criti (Sliding region) (5)
Cutting condition Dry
In the present work, tool and work contact was Spindle speed (RPM) 7500
defined using surface to surface contact. The
constraint provided was master-slave kinematic Feed (mm/tooth) 0.2
control. The tangential behavior of the contact surface
was defined using penalty contact with co-efficient of Radial depth of cut (mm) 0.2
friction value µ of 0.3 [Wang et al. (2010)]. One of the Axial depth of cut (mm) 25
advantages of using the modified Coulomb friction
model was that the solver determines the friction state
automatically according to the contact stress value 5 Results and discussion
during the simulation process. The preliminary results obtained during the
numerical simulation of machining thin-wall
3 Cutting conditions and process aluminum 7075-T6 alloy part are discussed in this
simulation section. The deflection measurement points are shown
in figure 4. The cutter moves along X-direction from
A 3D finite element simulation of thin-wall point ‘P’ to ‘V’. Deflection of part along X-direction
machining of A7075-T6 workpiece using an end at the end of cutting process is plotted in figure 5.
milling cutter is carried out. The J-C material model
parameters are assigned to the workpiece which takes
care of the mechanical properties during deformation.
Also a J-C material damage law was applied to
initiate the chip formation. The detailed cutting
conditions are listed in the table 5.
In the present work determination of the
deflection of the workpiece under the action of cutting
force is considered to be the main objective. Heat
generated and temperature rise during machining are
ignored for the ease of computation and memory
management. In the lagrangian formulation, the finite
element mesh is attached to the material and follows
its deformation. Lagrangian formulation is used to
analyze transient problems which undergo large
deformations. The milling process involves large
deformation and continuously changing contact. To
handle the large amount of nonlinearity, a dynamic
explicit time integration scheme is adopted. The
explicit dynamic analysis procedure implements the
explicit integration rule together with the use of
lumped mass matrix. The explicit procedure does not
require any iterations and tangent stiffness matrix. Figure 4 Deflection measurement points
The explicit procedure integrates through time by
using many small time increments. The explicit
formulation advances the solution in time with the
central difference scheme. The central-difference
operator is conditionally stable, and the stability limit
for the operator is based on the critical time step. The
critical time step for a mesh is considered to be the
minimum value of the element length taken over all
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5th International & 26th All India Manufacturing Technology, Design and Research Conference (AIMTDR 2014) December 12th–14th, 2014,
IIT Guwahati, Assam, India
Figure 7 shows the deflection of the work piece Figure 8 Comparison of form error obtained with
along Y-direction at various points of the surface of experiment and numerical simulation
the work part. It can be seen that the deflection at the
top edge is more as compared to the bottom portion of
the work part.This may be due the fact that the Numerical simulation can also be used to
inverted cantilever is just fixed at its bottom portion determine the surface roughness of a machined part.
whilst it’s top portion free and unconstrained to The surface finish of the machined thin-wall
deflect under the action of resultant force. Also the simulated part is shown in figure 9. It was observed
lower stiffness value leads to more deflection of free that under the action of cutting forces, the inverted
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3D finite element modeling of thin-wall machining of aluminum 7075-T6 alloy
cantilever workpiece undergoes cyclic deflections. of thin-walled parts with variable dynamics,
This was due the repeated cutter teeth engagement Proceedings of the 6th International conference on
and disengagement with the work part. This results in high speed machining, San Sebastian
non-uniform material removal and unevenly finished Gang, L. (2009), Study on deformation of titanium
surface. thin-walled part in milling process, Journal of
materials processing technology, Vol. 209, pp.2788–
2793
Johnson, G R. and Cook, W.H. (1983), A constitutive
model and data for metals subjected to large strains,
high strain rates, and high temperatures, Proceedings
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548
Johnson, G.R. and Cook, W.H. (1985), Fracture
characteristics of three metals subjected to various
strain, strain Rates, temperature, and pressures,
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pp.31-48
Mangalekar, N. (2012), Experimental studies on thin-
wall machining of aluminum 8011 alloy, M.Tech.
thesis, Indian Institute of Technology Guwahati, India
Pittalà, G.M. and Monno, M. (2010), 3D finite
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material, International Journal of Advanced
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Figure 9 Surface roughness observed in numerical Ratchev, S. Govender, E. Nikov, S. Phuah, K. and
simulation Tsiklos, G. (2003), Force and deflection modeling in
milling of low-rigidity complex parts, Journal of
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Conclusions pp.796-801
In the present work 3D transient nonlinear FEM Ratchev, S. Huang, W. Liu, S. Becker, A.A. (2004),
based numerical model of thin-wall milling Modeling and simulation environment for machining
wasdeveloped. Based on this model, a simulation of of low-rigidity components, Journal of materials
thin-wall machiningof aluminum 7075-T6 workpiece processing technology, Vol. 153-154, pp.67-73
was carried out and preliminary results are discussed. Sekiguchi, T. Kagiya, Y. and Goshima, Y. (2004),
The model successfully simulated the physical Cemented carbide end mill, U.S patent 6719501
interaction of helical cutter teeth with the work part Soo, S. L. Dewes, R.C. and Aspinwall, D.K. (2010),
surface. However it took approximately 100 hours. 3D FE modeling of the cutting of Inconel 718,
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define the workpiece material properties and chip Starke, E. A. and Staley, J. T. (1996), Application of
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compared with those available in published Aerospace Sciences, Vol. 32, pp.131-172
experimental work. It was observed that there was a Tanase, I. Ghionea, A. and Ghionea, I. (2010),
Measurement and analysis of cutting forces and
significant amount of deflection of thin-wall part due
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geometry was found to be agreed well with the Manufacturing Systems, Vol. 5, pp.243-248
experimental results. Based on this model, further Tang, A. and Liu, Z. (2008), Deformations of thin-
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