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Title:A finite element study of the mechanics of micro-groove machining of 4340 steel
Author(s):Chen, Xin
Advisor(s):Kapoor, Shiv G.
Department / Program:Mechanical Science & Engineering
Discipline:Mechanical Engineering
Degree Granting Institution:University of Illinois at Urbana-Champaign
Subject(s):Micro-groove cutting
Thermo-mechanical coupling finite element method (FEM)
Abstract:Microgroove features have been widely used in hot embossing molds, micro-heat exchangers, optical lithography masks, micro-forming dies, engineered surface textures, etc. The challenge of achieving such feature is the control of the process parameters to minimize the side burr that often damages the microgroove. Besides, there is a limitation of the experimental study on gathering the cutting performance information such as temperature, stress, and chip formation for the purpose of process improvements. Therefore, a 3D Finite Element (FE) model was developed to study the microgroove cutting process. However, the frictional heat has not been considered in the previous FE models and could have big impact on predictions of the side burr height, chip thickness, temperature in the chip, and the cutting force experienced by the tool. To better understand the process mechanics of micro-groove cutting, the 3D finite element model for microgroove machining of steel developed previously has been enhanced to include the friction heat generation. The side burr and chip formation were predicted and validated with experimental results in AISI 4340 steel, which showed that the model predicted side burr height within 6.7% and chip thickness within 3.3 % error. Various process mechanics including temperature distribution in the chip, cutting force predictions, and stress distribution in the workpiece were studied. It was found that coupling the thermal and mechanical effects, and including the friction heat improved the prediction of the cutting performance. It was also noticed that the cutting tool with a small edge radius and a larger rake angle experienced lower temperature, lower stresses, and smaller cutting forces on its rake face.
Issue Date:2015-12-09
Rights Information:Copyright 2015 Xin Chen
Date Available in IDEALS:2016-03-02
Date Deposited:2015-12

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