1. Single Point Turning of Materials Using FEM Simulations Presented by: Chris Wells Brant Liou

2. Single Point Turning of Materials Using FEM Simulations Background Information on Single-Point Turning Background Information on Single-Point Turning Elements of Single Point Turning Elements of Single Point Turning Material Cases: Material Cases:  Grade 410 Stainless Steel (Annealed)  Brass Material (As-Sintered)  Aluminum Alloy Al2024-T3511 (Cold-Drawn)  Inconel 718 FEM Model setup FEM Model setup Depth of Cut Depth of Cut Feed Feed Speed Speed Rake Angle Rake Angle Tool Material Tool Material FEM Results FEM Results Theories & Calculations Theories & Calculations Conclusion Conclusion

3. Elements of Single Point Turning (Orthogonal) Machining angles: Machining angles:  Rake angle, α  Friction Angle, λ  Shear Plane Angle, φ

4. Material Cases AISI Grade 4130 Alloy (Medium Carbon) AISI Grade 4130 Alloy (Medium Carbon) Hardness = 375 Bhn Hardness = 375 Bhn Yield Strength = 883 MPa Yield Strength = 883 MPa

5. Material Cases Type C37700 Brass Material Type C37700 Brass Material Hardness = 81 Bhn Hardness = 81 Bhn Yield Strength = 138 MPa Yield Strength = 138 MPa

6. Material Cases Al 2024-T3511 Hardness = 38 to 50 Bhn Hardness = 38 to 50 Bhn Yield Strength = 170MPa Yield Strength = 170MPa

7. Material Cases Iconel 718 Hardness = 454 Bhn Hardness = 454 Bhn Yield Strength = 1103MPa Yield Strength = 1103MPa

8. FEM Results AISI Grade 4130 Alloy (Medium Carbon) Input Parameters: Depth of Cut = 4 mm Feed = 0.4 mm/rev Speed = 100 m/min Rake Angle = 0 ° Cutting Radius = 0.02 mm Relief Angle = 10 ° Cutting Tool – HSS-General Click on the image to animate the results

9. FEM Results AISI Grade 4130 Alloy (Medium Carbon) AISI Grade 4130 Alloy (Medium Carbon) Rake Angle 0 0 Max Shear Stress 4623.12 MPa AISI Grade 4130 Alloy (Medium Carbon) AISI Grade 4130 Alloy (Medium Carbon) Rake Angle 45 0 Max Shear Stress 5996.24 MPa

10. FEM Results AISI Grade 4130 Alloy (Medium Carbon) Rake Angle 0 0 Cutting & Thrust Forces AISI Grade 4130 Alloy (Medium Carbon) AISI Grade 4130 Alloy (Medium Carbon) Rake Angle 45 0 Cutting & Thrust Forces

11. FEM Results AISI Grade 4130 Alloy (Medium Carbon) AISI Grade 4130 Alloy (Medium Carbon) Rake Angle 0 0 Max Von Mises Stress 8060.08 MPa AISI Grade 4130 Alloy (Medium Carbon) AISI Grade 4130 Alloy (Medium Carbon) Rake Angle 45 0 Max Von Mises Stress 12725.1 MPa

12. FEM Results AISI Grade 4130 Alloy (Medium Carbon) AISI Grade 4130 Alloy (Medium Carbon) Rake Angle 0 0 Max Temperature 603.08 AISI Grade 4130 Alloy (Medium Carbon) AISI Grade 4130 Alloy (Medium Carbon) Rake Angle 45 0 Max Temperature 516.749

13. FEM Results AISI Grade 4130 Alloy (Medium Carbon) AISI Grade 4130 Alloy (Medium Carbon) Rake Angle 0 0 Max Pressure 5315.14 AISI Grade 4130 Alloy (Medium Carbon) AISI Grade 4130 Alloy (Medium Carbon) Brass Rake Angle 45 0 Max Pressure 15906.1

14. FEM Results Type C37700 Brass Input Parameters: Depth of Cut = 4 mm Feed = 0.4 mm/rev Speed = 100 m/min Rake Angle = 0 ° Cutting Radius = 0.02 mm Relief Angle = 10 ° Cutting Tool – HSS- General Click on the image to animate the results

15. FEM Results Type C37700 Brass Rake Angle 0 0 Max Shear Stress 2044.74 MPa Type C37700 Brass Rake Angle 45 0 Max Shear Stress 1598.75

16. FEM Results Type C37700 Brass Rake Angle 0 0 Cutting & Thrust Forces Type C37700 Brass Rake Angle 45 0 Cutting & Thrust Forces

17. FEM Results Type C37700 Brass Rake Angle 0 0 Max Von Mises Stress 3928.02 MPa Type C37700 Brass Rake Angle 45 0 Max Von Mises Stress 2896.23

18. FEM Results Type C37700 Brass Rake Angle 0 0 Max Temperature 358.41 Type C37700 Brass Rake Angle 45 0 Max Temperature 305.29

19. FEM Results Type C37700 Brass Rake Angle 0 0 Plastic Strain Type C37700 Brass Rake Angle 45 0 Plastic Strain

20. FEM Results Type C37700 Brass Rake Angle 0 0 Max Pressure 3668.05 Type C37700 Brass Rake Angle 45 0 Max Pressure 1797.33

21. FEM Results Al 2024-T3511 (Cold Drawn) Al 2024-T3511 (Cold Drawn) Input Parameters: Input Parameters: Depth of Cut = 4 mm Depth of Cut = 4 mm Feed = 0.4 mm/rev Feed = 0.4 mm/rev Speed = 275 m/min Speed = 275 m/min Rake Angle = 0 ° Rake Angle = 0 ° Cutting Radius = 0.02 mm Cutting Radius = 0.02 mm Relief Angle = 10 ° Relief Angle = 10 ° Cutting Tool – HSS-General Cutting Tool – HSS-General Click on the image to animate the results

22. FEM Results Al 2024-T3511 Rake Angle 15 0 Max Temp 334 Deg C Al 2024-T3511 Rake Angle -15 0 Max Temp 350 Deg C

23. FEM Results Al 2024-T3511 Rake Angle 15 0 Plastic Strain Al 2024-T3511 Rake Angle -15 0 Plastic Strain

24. FEM Results Al 2024-T3511 Rake Angle 15 0 Cutting & Thrust Force Al 2024-T3511 Rake Angle -15 0 Cutting & Thrust Force

25. FEM Results Al 2024-T3511 Rake Angle 15 0 Max Von Mises Stress 3573 MPa Al 2024-T3511 Rake Angle -15 0 Max Von Mises Stress 2950 MPa

26. FEM Results Al 2024-T3511 Rake Angle 15 0 Max Shear Stress 1887 MPa Al 2024-T3511 Rake Angle -15 0 Max Shear Stress 1589 MPa

27. FEM Results Al 2024-T3511 Rake Angle 15 0 Max Pressure 3120 MPa Al 2024-T3511 Rake Angle -15 0 Max Pressure 2261 MPa

28. FEM Results Inconel 718 Inconel 718 Input Parameters: Input Parameters: Depth of Cut = 4 mm Depth of Cut = 4 mm Feed = 0.25 mm/rev Feed = 0.25 mm/rev Speed = 23 m/min Speed = 23 m/min Rake Angle = 0 ° Rake Angle = 0 ° Cutting Radius = 0.02 mm Cutting Radius = 0.02 mm Relief Angle = 10 ° Relief Angle = 10 ° Cutting Tool – HSS-General Cutting Tool – HSS-General Click on the image to animate the results

29. FEM Results Inconel 718 Rake Angle 15 0 Max Temp 820 Deg C Inconel 718 Rake Angle -15 0 Max Temp 814 Deg C

30. FEM Results Inconel 718 Rake Angle 15 0 Plastic Strain Inconel 718 Rake Angle -15 0 Plastic Strain

31. FEM Results Inconel 718 Rake Angle 15 0 Cutting & Thrust Force Inconel 718 Rake Angle -15 0 Cutting & Thrust Force

32. FEM Results Inconel 718 Rake Angle 15 0 Max Von Mises Stress 14526 MPa Inconel 718 Rake Angle -15 0 Max Von Mises Stress 6852 MPa

33. FEM Results Inconel 718 Rake Angle 15 0 Max Shear Stress 7305 MPa Inconel 718 Rake Angle -15 0 Max Shear Stress 2845 MPa

34. FEM Results Inconel 718 Rake Angle 15 0 Max Pressure 15427 MPa Inconel Rake Angle -15 0 Max Pressure 11186 MPa

35. FEM Results Inconel 718 Inconel 718 Input Parameters: Input Parameters: Depth of Cut = 4 mm Depth of Cut = 4 mm Feed = 0.25 mm/rev Feed = 0.25 mm/rev Speed = 23 m/min Speed = 23 m/min Rake Angle = 0 ° Rake Angle = 0 ° Cutting Radius = 0.02 mm Cutting Radius = 0.02 mm Relief Angle = 10 ° Relief Angle = 10 ° Cutting Tool – HSS-General Cutting Tool – HSS-General Cutting Tool – Carbide General Cutting Tool – Carbide General HSS Carbide

36. Theories & Calculations  Friction Angle Calculation: Al 2024-T3511 Rake Angle 0 0 tan -1 (0.25)=14 λ = 14 0 λ = 14 0

37. Theories & Calculations

38. Theories & Calculations (Cont.)

39. Conclusion

40. References Metal Machining - Theory and Applications By: Childs, T.H.C.; Maekawa, K.; Obikawa, T.; Yamane, Y. © 2000 Elsevier Metal Machining - Theory and Applications By: Childs, T.H.C.; Maekawa, K.; Obikawa, T.; Yamane, Y. © 2000 Elsevier M.C. Shaw, Metal Cutting Principles, 2nd ed., Oxford U.P., New York, 2005 M.C. Shaw, Metal Cutting Principles, 2nd ed., Oxford U.P., New York, 2005 Third Wave AdvantEdge User Manual Third Wave AdvantEdge User Manual