Meso-scale tool breakage prediction based on finite element stress analysis for shoulder milling of hardened steel
In this article, finite element method (FEM) based tool stress analysis and breakage prediction are advanced for meso-scale shoulder milling of hardened stainless steel. Rather than using simplified line loads or uniformly distributed loads, the tool stress analyses are conducted with realistic chip...
Ausführliche Beschreibung
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| Autor*in: |
Gao, Yifan [verfasserIn] |
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| Format: |
E-Artikel |
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| Sprache: |
Englisch |
| Erschienen: |
2020transfer abstract |
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| Schlagwörter: |
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| Umfang: |
10 |
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| Übergeordnetes Werk: |
Enthalten in: Tilting at windmills? Electoral repercussions of wind turbine projects in Minnesota - Bayulgen, Oksan ELSEVIER, 2021, Dearborn, Mich |
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| Übergeordnetes Werk: |
volume:55 ; year:2020 ; pages:31-40 ; extent:10 |
| Links: |
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| DOI / URN: |
10.1016/j.jmapro.2020.03.044 |
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ELV050614711 |
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| 245 | 1 | 0 | |a Meso-scale tool breakage prediction based on finite element stress analysis for shoulder milling of hardened steel |
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| 520 | |a In this article, finite element method (FEM) based tool stress analysis and breakage prediction are advanced for meso-scale shoulder milling of hardened stainless steel. Rather than using simplified line loads or uniformly distributed loads, the tool stress analyses are conducted with realistic chip load predicted by the previously developed 3D coupled Eulerian-Lagrangian (CEL) FEM model. A reliable distribution of contact forces obtained with a continuous tool-chip contact region is transferred to a static FEM model for tool stress analysis and breakage prediction at each angular location of an end mill. The simulation results are validated through dedicated cutting experiments with short cutting distances under various cutting conditions. The developed FEM models are found to be capable of making accurate predictions of tool breakage. Some key features of feed rate-related tool breakage are identified. It is found that the maximum tensile stress in the tool does not coincide with the maximum resultant cutting force in terms of cutter rotation. The tensile stress in the tool is not positively correlated with the resultant cutting force. In down milling, the maximum tensile stress is found to occur just after the tool starts to contact with the workpiece. It is also observed that the tensile stresses of the tool are much smaller in up milling configuration compared to down milling processes. | ||
| 520 | |a In this article, finite element method (FEM) based tool stress analysis and breakage prediction are advanced for meso-scale shoulder milling of hardened stainless steel. Rather than using simplified line loads or uniformly distributed loads, the tool stress analyses are conducted with realistic chip load predicted by the previously developed 3D coupled Eulerian-Lagrangian (CEL) FEM model. A reliable distribution of contact forces obtained with a continuous tool-chip contact region is transferred to a static FEM model for tool stress analysis and breakage prediction at each angular location of an end mill. The simulation results are validated through dedicated cutting experiments with short cutting distances under various cutting conditions. The developed FEM models are found to be capable of making accurate predictions of tool breakage. Some key features of feed rate-related tool breakage are identified. It is found that the maximum tensile stress in the tool does not coincide with the maximum resultant cutting force in terms of cutter rotation. The tensile stress in the tool is not positively correlated with the resultant cutting force. In down milling, the maximum tensile stress is found to occur just after the tool starts to contact with the workpiece. It is also observed that the tensile stresses of the tool are much smaller in up milling configuration compared to down milling processes. | ||
| 650 | 7 | |a Tool breakage prediction |2 Elsevier | |
| 650 | 7 | |a tool stress analysis |2 Elsevier | |
| 650 | 7 | |a Finite element method (FEM) |2 Elsevier | |
| 650 | 7 | |a Coupled Eulerian-Lagrangian (CEL) |2 Elsevier | |
| 700 | 1 | |a Ko, Jeong Hoon |4 oth | |
| 700 | 1 | |a Lee, Heow Pueh |4 oth | |
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10.1016/j.jmapro.2020.03.044 doi /cbs_pica/cbs_olc/import_discovery/elsevier/einzuspielen/GBV00000000001257.pica (DE-627)ELV050614711 (ELSEVIER)S1526-6125(20)30184-5 DE-627 ger DE-627 rakwb eng 620 VZ 83.65 bkl Gao, Yifan verfasserin aut Meso-scale tool breakage prediction based on finite element stress analysis for shoulder milling of hardened steel 2020transfer abstract 10 nicht spezifiziert zzz rdacontent nicht spezifiziert z rdamedia nicht spezifiziert zu rdacarrier In this article, finite element method (FEM) based tool stress analysis and breakage prediction are advanced for meso-scale shoulder milling of hardened stainless steel. Rather than using simplified line loads or uniformly distributed loads, the tool stress analyses are conducted with realistic chip load predicted by the previously developed 3D coupled Eulerian-Lagrangian (CEL) FEM model. A reliable distribution of contact forces obtained with a continuous tool-chip contact region is transferred to a static FEM model for tool stress analysis and breakage prediction at each angular location of an end mill. The simulation results are validated through dedicated cutting experiments with short cutting distances under various cutting conditions. The developed FEM models are found to be capable of making accurate predictions of tool breakage. Some key features of feed rate-related tool breakage are identified. It is found that the maximum tensile stress in the tool does not coincide with the maximum resultant cutting force in terms of cutter rotation. The tensile stress in the tool is not positively correlated with the resultant cutting force. In down milling, the maximum tensile stress is found to occur just after the tool starts to contact with the workpiece. It is also observed that the tensile stresses of the tool are much smaller in up milling configuration compared to down milling processes. In this article, finite element method (FEM) based tool stress analysis and breakage prediction are advanced for meso-scale shoulder milling of hardened stainless steel. Rather than using simplified line loads or uniformly distributed loads, the tool stress analyses are conducted with realistic chip load predicted by the previously developed 3D coupled Eulerian-Lagrangian (CEL) FEM model. A reliable distribution of contact forces obtained with a continuous tool-chip contact region is transferred to a static FEM model for tool stress analysis and breakage prediction at each angular location of an end mill. The simulation results are validated through dedicated cutting experiments with short cutting distances under various cutting conditions. The developed FEM models are found to be capable of making accurate predictions of tool breakage. Some key features of feed rate-related tool breakage are identified. It is found that the maximum tensile stress in the tool does not coincide with the maximum resultant cutting force in terms of cutter rotation. The tensile stress in the tool is not positively correlated with the resultant cutting force. In down milling, the maximum tensile stress is found to occur just after the tool starts to contact with the workpiece. It is also observed that the tensile stresses of the tool are much smaller in up milling configuration compared to down milling processes. Tool breakage prediction Elsevier tool stress analysis Elsevier Finite element method (FEM) Elsevier Coupled Eulerian-Lagrangian (CEL) Elsevier Ko, Jeong Hoon oth Lee, Heow Pueh oth Enthalten in Soc Bayulgen, Oksan ELSEVIER Tilting at windmills? Electoral repercussions of wind turbine projects in Minnesota 2021 Dearborn, Mich (DE-627)ELV00685088X volume:55 year:2020 pages:31-40 extent:10 https://doi.org/10.1016/j.jmapro.2020.03.044 Volltext GBV_USEFLAG_U GBV_ELV SYSFLAG_U 83.65 Versorgungswirtschaft VZ AR 55 2020 31-40 10 |
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10.1016/j.jmapro.2020.03.044 doi /cbs_pica/cbs_olc/import_discovery/elsevier/einzuspielen/GBV00000000001257.pica (DE-627)ELV050614711 (ELSEVIER)S1526-6125(20)30184-5 DE-627 ger DE-627 rakwb eng 620 VZ 83.65 bkl Gao, Yifan verfasserin aut Meso-scale tool breakage prediction based on finite element stress analysis for shoulder milling of hardened steel 2020transfer abstract 10 nicht spezifiziert zzz rdacontent nicht spezifiziert z rdamedia nicht spezifiziert zu rdacarrier In this article, finite element method (FEM) based tool stress analysis and breakage prediction are advanced for meso-scale shoulder milling of hardened stainless steel. Rather than using simplified line loads or uniformly distributed loads, the tool stress analyses are conducted with realistic chip load predicted by the previously developed 3D coupled Eulerian-Lagrangian (CEL) FEM model. A reliable distribution of contact forces obtained with a continuous tool-chip contact region is transferred to a static FEM model for tool stress analysis and breakage prediction at each angular location of an end mill. The simulation results are validated through dedicated cutting experiments with short cutting distances under various cutting conditions. The developed FEM models are found to be capable of making accurate predictions of tool breakage. Some key features of feed rate-related tool breakage are identified. It is found that the maximum tensile stress in the tool does not coincide with the maximum resultant cutting force in terms of cutter rotation. The tensile stress in the tool is not positively correlated with the resultant cutting force. In down milling, the maximum tensile stress is found to occur just after the tool starts to contact with the workpiece. It is also observed that the tensile stresses of the tool are much smaller in up milling configuration compared to down milling processes. In this article, finite element method (FEM) based tool stress analysis and breakage prediction are advanced for meso-scale shoulder milling of hardened stainless steel. Rather than using simplified line loads or uniformly distributed loads, the tool stress analyses are conducted with realistic chip load predicted by the previously developed 3D coupled Eulerian-Lagrangian (CEL) FEM model. A reliable distribution of contact forces obtained with a continuous tool-chip contact region is transferred to a static FEM model for tool stress analysis and breakage prediction at each angular location of an end mill. The simulation results are validated through dedicated cutting experiments with short cutting distances under various cutting conditions. The developed FEM models are found to be capable of making accurate predictions of tool breakage. Some key features of feed rate-related tool breakage are identified. It is found that the maximum tensile stress in the tool does not coincide with the maximum resultant cutting force in terms of cutter rotation. The tensile stress in the tool is not positively correlated with the resultant cutting force. In down milling, the maximum tensile stress is found to occur just after the tool starts to contact with the workpiece. It is also observed that the tensile stresses of the tool are much smaller in up milling configuration compared to down milling processes. Tool breakage prediction Elsevier tool stress analysis Elsevier Finite element method (FEM) Elsevier Coupled Eulerian-Lagrangian (CEL) Elsevier Ko, Jeong Hoon oth Lee, Heow Pueh oth Enthalten in Soc Bayulgen, Oksan ELSEVIER Tilting at windmills? Electoral repercussions of wind turbine projects in Minnesota 2021 Dearborn, Mich (DE-627)ELV00685088X volume:55 year:2020 pages:31-40 extent:10 https://doi.org/10.1016/j.jmapro.2020.03.044 Volltext GBV_USEFLAG_U GBV_ELV SYSFLAG_U 83.65 Versorgungswirtschaft VZ AR 55 2020 31-40 10 |
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10.1016/j.jmapro.2020.03.044 doi /cbs_pica/cbs_olc/import_discovery/elsevier/einzuspielen/GBV00000000001257.pica (DE-627)ELV050614711 (ELSEVIER)S1526-6125(20)30184-5 DE-627 ger DE-627 rakwb eng 620 VZ 83.65 bkl Gao, Yifan verfasserin aut Meso-scale tool breakage prediction based on finite element stress analysis for shoulder milling of hardened steel 2020transfer abstract 10 nicht spezifiziert zzz rdacontent nicht spezifiziert z rdamedia nicht spezifiziert zu rdacarrier In this article, finite element method (FEM) based tool stress analysis and breakage prediction are advanced for meso-scale shoulder milling of hardened stainless steel. Rather than using simplified line loads or uniformly distributed loads, the tool stress analyses are conducted with realistic chip load predicted by the previously developed 3D coupled Eulerian-Lagrangian (CEL) FEM model. A reliable distribution of contact forces obtained with a continuous tool-chip contact region is transferred to a static FEM model for tool stress analysis and breakage prediction at each angular location of an end mill. The simulation results are validated through dedicated cutting experiments with short cutting distances under various cutting conditions. The developed FEM models are found to be capable of making accurate predictions of tool breakage. Some key features of feed rate-related tool breakage are identified. It is found that the maximum tensile stress in the tool does not coincide with the maximum resultant cutting force in terms of cutter rotation. The tensile stress in the tool is not positively correlated with the resultant cutting force. In down milling, the maximum tensile stress is found to occur just after the tool starts to contact with the workpiece. It is also observed that the tensile stresses of the tool are much smaller in up milling configuration compared to down milling processes. In this article, finite element method (FEM) based tool stress analysis and breakage prediction are advanced for meso-scale shoulder milling of hardened stainless steel. Rather than using simplified line loads or uniformly distributed loads, the tool stress analyses are conducted with realistic chip load predicted by the previously developed 3D coupled Eulerian-Lagrangian (CEL) FEM model. A reliable distribution of contact forces obtained with a continuous tool-chip contact region is transferred to a static FEM model for tool stress analysis and breakage prediction at each angular location of an end mill. The simulation results are validated through dedicated cutting experiments with short cutting distances under various cutting conditions. The developed FEM models are found to be capable of making accurate predictions of tool breakage. Some key features of feed rate-related tool breakage are identified. It is found that the maximum tensile stress in the tool does not coincide with the maximum resultant cutting force in terms of cutter rotation. The tensile stress in the tool is not positively correlated with the resultant cutting force. In down milling, the maximum tensile stress is found to occur just after the tool starts to contact with the workpiece. It is also observed that the tensile stresses of the tool are much smaller in up milling configuration compared to down milling processes. Tool breakage prediction Elsevier tool stress analysis Elsevier Finite element method (FEM) Elsevier Coupled Eulerian-Lagrangian (CEL) Elsevier Ko, Jeong Hoon oth Lee, Heow Pueh oth Enthalten in Soc Bayulgen, Oksan ELSEVIER Tilting at windmills? Electoral repercussions of wind turbine projects in Minnesota 2021 Dearborn, Mich (DE-627)ELV00685088X volume:55 year:2020 pages:31-40 extent:10 https://doi.org/10.1016/j.jmapro.2020.03.044 Volltext GBV_USEFLAG_U GBV_ELV SYSFLAG_U 83.65 Versorgungswirtschaft VZ AR 55 2020 31-40 10 |
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10.1016/j.jmapro.2020.03.044 doi /cbs_pica/cbs_olc/import_discovery/elsevier/einzuspielen/GBV00000000001257.pica (DE-627)ELV050614711 (ELSEVIER)S1526-6125(20)30184-5 DE-627 ger DE-627 rakwb eng 620 VZ 83.65 bkl Gao, Yifan verfasserin aut Meso-scale tool breakage prediction based on finite element stress analysis for shoulder milling of hardened steel 2020transfer abstract 10 nicht spezifiziert zzz rdacontent nicht spezifiziert z rdamedia nicht spezifiziert zu rdacarrier In this article, finite element method (FEM) based tool stress analysis and breakage prediction are advanced for meso-scale shoulder milling of hardened stainless steel. Rather than using simplified line loads or uniformly distributed loads, the tool stress analyses are conducted with realistic chip load predicted by the previously developed 3D coupled Eulerian-Lagrangian (CEL) FEM model. A reliable distribution of contact forces obtained with a continuous tool-chip contact region is transferred to a static FEM model for tool stress analysis and breakage prediction at each angular location of an end mill. The simulation results are validated through dedicated cutting experiments with short cutting distances under various cutting conditions. The developed FEM models are found to be capable of making accurate predictions of tool breakage. Some key features of feed rate-related tool breakage are identified. It is found that the maximum tensile stress in the tool does not coincide with the maximum resultant cutting force in terms of cutter rotation. The tensile stress in the tool is not positively correlated with the resultant cutting force. In down milling, the maximum tensile stress is found to occur just after the tool starts to contact with the workpiece. It is also observed that the tensile stresses of the tool are much smaller in up milling configuration compared to down milling processes. In this article, finite element method (FEM) based tool stress analysis and breakage prediction are advanced for meso-scale shoulder milling of hardened stainless steel. Rather than using simplified line loads or uniformly distributed loads, the tool stress analyses are conducted with realistic chip load predicted by the previously developed 3D coupled Eulerian-Lagrangian (CEL) FEM model. A reliable distribution of contact forces obtained with a continuous tool-chip contact region is transferred to a static FEM model for tool stress analysis and breakage prediction at each angular location of an end mill. The simulation results are validated through dedicated cutting experiments with short cutting distances under various cutting conditions. The developed FEM models are found to be capable of making accurate predictions of tool breakage. Some key features of feed rate-related tool breakage are identified. It is found that the maximum tensile stress in the tool does not coincide with the maximum resultant cutting force in terms of cutter rotation. The tensile stress in the tool is not positively correlated with the resultant cutting force. In down milling, the maximum tensile stress is found to occur just after the tool starts to contact with the workpiece. It is also observed that the tensile stresses of the tool are much smaller in up milling configuration compared to down milling processes. Tool breakage prediction Elsevier tool stress analysis Elsevier Finite element method (FEM) Elsevier Coupled Eulerian-Lagrangian (CEL) Elsevier Ko, Jeong Hoon oth Lee, Heow Pueh oth Enthalten in Soc Bayulgen, Oksan ELSEVIER Tilting at windmills? Electoral repercussions of wind turbine projects in Minnesota 2021 Dearborn, Mich (DE-627)ELV00685088X volume:55 year:2020 pages:31-40 extent:10 https://doi.org/10.1016/j.jmapro.2020.03.044 Volltext GBV_USEFLAG_U GBV_ELV SYSFLAG_U 83.65 Versorgungswirtschaft VZ AR 55 2020 31-40 10 |
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10.1016/j.jmapro.2020.03.044 doi /cbs_pica/cbs_olc/import_discovery/elsevier/einzuspielen/GBV00000000001257.pica (DE-627)ELV050614711 (ELSEVIER)S1526-6125(20)30184-5 DE-627 ger DE-627 rakwb eng 620 VZ 83.65 bkl Gao, Yifan verfasserin aut Meso-scale tool breakage prediction based on finite element stress analysis for shoulder milling of hardened steel 2020transfer abstract 10 nicht spezifiziert zzz rdacontent nicht spezifiziert z rdamedia nicht spezifiziert zu rdacarrier In this article, finite element method (FEM) based tool stress analysis and breakage prediction are advanced for meso-scale shoulder milling of hardened stainless steel. Rather than using simplified line loads or uniformly distributed loads, the tool stress analyses are conducted with realistic chip load predicted by the previously developed 3D coupled Eulerian-Lagrangian (CEL) FEM model. A reliable distribution of contact forces obtained with a continuous tool-chip contact region is transferred to a static FEM model for tool stress analysis and breakage prediction at each angular location of an end mill. The simulation results are validated through dedicated cutting experiments with short cutting distances under various cutting conditions. The developed FEM models are found to be capable of making accurate predictions of tool breakage. Some key features of feed rate-related tool breakage are identified. It is found that the maximum tensile stress in the tool does not coincide with the maximum resultant cutting force in terms of cutter rotation. The tensile stress in the tool is not positively correlated with the resultant cutting force. In down milling, the maximum tensile stress is found to occur just after the tool starts to contact with the workpiece. It is also observed that the tensile stresses of the tool are much smaller in up milling configuration compared to down milling processes. In this article, finite element method (FEM) based tool stress analysis and breakage prediction are advanced for meso-scale shoulder milling of hardened stainless steel. Rather than using simplified line loads or uniformly distributed loads, the tool stress analyses are conducted with realistic chip load predicted by the previously developed 3D coupled Eulerian-Lagrangian (CEL) FEM model. A reliable distribution of contact forces obtained with a continuous tool-chip contact region is transferred to a static FEM model for tool stress analysis and breakage prediction at each angular location of an end mill. The simulation results are validated through dedicated cutting experiments with short cutting distances under various cutting conditions. The developed FEM models are found to be capable of making accurate predictions of tool breakage. Some key features of feed rate-related tool breakage are identified. It is found that the maximum tensile stress in the tool does not coincide with the maximum resultant cutting force in terms of cutter rotation. The tensile stress in the tool is not positively correlated with the resultant cutting force. In down milling, the maximum tensile stress is found to occur just after the tool starts to contact with the workpiece. It is also observed that the tensile stresses of the tool are much smaller in up milling configuration compared to down milling processes. Tool breakage prediction Elsevier tool stress analysis Elsevier Finite element method (FEM) Elsevier Coupled Eulerian-Lagrangian (CEL) Elsevier Ko, Jeong Hoon oth Lee, Heow Pueh oth Enthalten in Soc Bayulgen, Oksan ELSEVIER Tilting at windmills? Electoral repercussions of wind turbine projects in Minnesota 2021 Dearborn, Mich (DE-627)ELV00685088X volume:55 year:2020 pages:31-40 extent:10 https://doi.org/10.1016/j.jmapro.2020.03.044 Volltext GBV_USEFLAG_U GBV_ELV SYSFLAG_U 83.65 Versorgungswirtschaft VZ AR 55 2020 31-40 10 |
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<?xml version="1.0" encoding="UTF-8"?><collection xmlns="http://www.loc.gov/MARC21/slim"><record><leader>01000caa a22002652 4500</leader><controlfield tag="001">ELV050614711</controlfield><controlfield tag="003">DE-627</controlfield><controlfield tag="005">20230626030857.0</controlfield><controlfield tag="007">cr uuu---uuuuu</controlfield><controlfield tag="008">200625s2020 xx |||||o 00| ||eng c</controlfield><datafield tag="024" ind1="7" ind2=" "><subfield code="a">10.1016/j.jmapro.2020.03.044</subfield><subfield code="2">doi</subfield></datafield><datafield tag="028" ind1="5" ind2="2"><subfield code="a">/cbs_pica/cbs_olc/import_discovery/elsevier/einzuspielen/GBV00000000001257.pica</subfield></datafield><datafield tag="035" ind1=" " ind2=" "><subfield code="a">(DE-627)ELV050614711</subfield></datafield><datafield tag="035" ind1=" " ind2=" "><subfield code="a">(ELSEVIER)S1526-6125(20)30184-5</subfield></datafield><datafield tag="040" ind1=" " ind2=" "><subfield code="a">DE-627</subfield><subfield code="b">ger</subfield><subfield code="c">DE-627</subfield><subfield code="e">rakwb</subfield></datafield><datafield tag="041" ind1=" " ind2=" "><subfield code="a">eng</subfield></datafield><datafield tag="082" ind1="0" ind2="4"><subfield code="a">620</subfield><subfield code="q">VZ</subfield></datafield><datafield tag="084" ind1=" " ind2=" "><subfield code="a">83.65</subfield><subfield code="2">bkl</subfield></datafield><datafield tag="100" ind1="1" ind2=" "><subfield code="a">Gao, Yifan</subfield><subfield code="e">verfasserin</subfield><subfield code="4">aut</subfield></datafield><datafield tag="245" ind1="1" ind2="0"><subfield code="a">Meso-scale tool breakage prediction based on finite element stress analysis for shoulder milling of hardened steel</subfield></datafield><datafield tag="264" ind1=" " ind2="1"><subfield code="c">2020transfer abstract</subfield></datafield><datafield tag="300" ind1=" " ind2=" "><subfield code="a">10</subfield></datafield><datafield tag="336" ind1=" " ind2=" "><subfield code="a">nicht spezifiziert</subfield><subfield code="b">zzz</subfield><subfield code="2">rdacontent</subfield></datafield><datafield tag="337" ind1=" " ind2=" "><subfield code="a">nicht spezifiziert</subfield><subfield code="b">z</subfield><subfield code="2">rdamedia</subfield></datafield><datafield tag="338" ind1=" " ind2=" "><subfield code="a">nicht spezifiziert</subfield><subfield code="b">zu</subfield><subfield code="2">rdacarrier</subfield></datafield><datafield tag="520" ind1=" " ind2=" "><subfield code="a">In this article, finite element method (FEM) based tool stress analysis and breakage prediction are advanced for meso-scale shoulder milling of hardened stainless steel. Rather than using simplified line loads or uniformly distributed loads, the tool stress analyses are conducted with realistic chip load predicted by the previously developed 3D coupled Eulerian-Lagrangian (CEL) FEM model. A reliable distribution of contact forces obtained with a continuous tool-chip contact region is transferred to a static FEM model for tool stress analysis and breakage prediction at each angular location of an end mill. The simulation results are validated through dedicated cutting experiments with short cutting distances under various cutting conditions. The developed FEM models are found to be capable of making accurate predictions of tool breakage. Some key features of feed rate-related tool breakage are identified. It is found that the maximum tensile stress in the tool does not coincide with the maximum resultant cutting force in terms of cutter rotation. The tensile stress in the tool is not positively correlated with the resultant cutting force. In down milling, the maximum tensile stress is found to occur just after the tool starts to contact with the workpiece. It is also observed that the tensile stresses of the tool are much smaller in up milling configuration compared to down milling processes.</subfield></datafield><datafield tag="520" ind1=" " ind2=" "><subfield code="a">In this article, finite element method (FEM) based tool stress analysis and breakage prediction are advanced for meso-scale shoulder milling of hardened stainless steel. Rather than using simplified line loads or uniformly distributed loads, the tool stress analyses are conducted with realistic chip load predicted by the previously developed 3D coupled Eulerian-Lagrangian (CEL) FEM model. A reliable distribution of contact forces obtained with a continuous tool-chip contact region is transferred to a static FEM model for tool stress analysis and breakage prediction at each angular location of an end mill. 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meso-scale tool breakage prediction based on finite element stress analysis for shoulder milling of hardened steel |
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Meso-scale tool breakage prediction based on finite element stress analysis for shoulder milling of hardened steel |
| abstract |
In this article, finite element method (FEM) based tool stress analysis and breakage prediction are advanced for meso-scale shoulder milling of hardened stainless steel. Rather than using simplified line loads or uniformly distributed loads, the tool stress analyses are conducted with realistic chip load predicted by the previously developed 3D coupled Eulerian-Lagrangian (CEL) FEM model. A reliable distribution of contact forces obtained with a continuous tool-chip contact region is transferred to a static FEM model for tool stress analysis and breakage prediction at each angular location of an end mill. The simulation results are validated through dedicated cutting experiments with short cutting distances under various cutting conditions. The developed FEM models are found to be capable of making accurate predictions of tool breakage. Some key features of feed rate-related tool breakage are identified. It is found that the maximum tensile stress in the tool does not coincide with the maximum resultant cutting force in terms of cutter rotation. The tensile stress in the tool is not positively correlated with the resultant cutting force. In down milling, the maximum tensile stress is found to occur just after the tool starts to contact with the workpiece. It is also observed that the tensile stresses of the tool are much smaller in up milling configuration compared to down milling processes. |
| abstractGer |
In this article, finite element method (FEM) based tool stress analysis and breakage prediction are advanced for meso-scale shoulder milling of hardened stainless steel. Rather than using simplified line loads or uniformly distributed loads, the tool stress analyses are conducted with realistic chip load predicted by the previously developed 3D coupled Eulerian-Lagrangian (CEL) FEM model. A reliable distribution of contact forces obtained with a continuous tool-chip contact region is transferred to a static FEM model for tool stress analysis and breakage prediction at each angular location of an end mill. The simulation results are validated through dedicated cutting experiments with short cutting distances under various cutting conditions. The developed FEM models are found to be capable of making accurate predictions of tool breakage. Some key features of feed rate-related tool breakage are identified. It is found that the maximum tensile stress in the tool does not coincide with the maximum resultant cutting force in terms of cutter rotation. The tensile stress in the tool is not positively correlated with the resultant cutting force. In down milling, the maximum tensile stress is found to occur just after the tool starts to contact with the workpiece. It is also observed that the tensile stresses of the tool are much smaller in up milling configuration compared to down milling processes. |
| abstract_unstemmed |
In this article, finite element method (FEM) based tool stress analysis and breakage prediction are advanced for meso-scale shoulder milling of hardened stainless steel. Rather than using simplified line loads or uniformly distributed loads, the tool stress analyses are conducted with realistic chip load predicted by the previously developed 3D coupled Eulerian-Lagrangian (CEL) FEM model. A reliable distribution of contact forces obtained with a continuous tool-chip contact region is transferred to a static FEM model for tool stress analysis and breakage prediction at each angular location of an end mill. The simulation results are validated through dedicated cutting experiments with short cutting distances under various cutting conditions. The developed FEM models are found to be capable of making accurate predictions of tool breakage. Some key features of feed rate-related tool breakage are identified. It is found that the maximum tensile stress in the tool does not coincide with the maximum resultant cutting force in terms of cutter rotation. The tensile stress in the tool is not positively correlated with the resultant cutting force. In down milling, the maximum tensile stress is found to occur just after the tool starts to contact with the workpiece. It is also observed that the tensile stresses of the tool are much smaller in up milling configuration compared to down milling processes. |
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Meso-scale tool breakage prediction based on finite element stress analysis for shoulder milling of hardened steel |
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