An abaqus-based 3D computer aided design, modelling and simulation of the end-milling operation of stainless steel 301.
Daniyan, Ilesanmi Mpofu, Khumbulani Ramatsetse, Boitumelo Muvunzi, Rumbidzai
Daniyan, Ilesanmi
Mpofu, Khumbulani
Ramatsetse, Boitumelo
Muvunzi, Rumbidzai
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Abstract
The need to improve the quality of products, to reduce the machining costs, and to maximize the profit rate calls for deployment of accurate optimisation model for predicting various parameters during milling operation in the manufacturing industries. Incorrect selection of cutting conditions often leads to most defects in milling operations such as inaccuracies in a feature's dimensions or surface roughness, thus compromises the quality of the work-piece being produced. To address the above mentioned issues, this research work employs a computer-aided based modelling and simulation approach to investigate the stress, strain, displacement and thermal distributions during the end milling operation of duplex stainless steel 301. The computer-aided design, modelling and simulation of the milling operation of the material was performed using the commercial software code ABAQUS. A dynamic coupled temperature displacement computation was employed in the explicit module of the ABAQUS software. The cutting tool and the work piece was first modelled and their computer aided design (CAD) models were imported into the module that is meshed with structured 8-node thermally coupled brick, trilinear displacement and temperature (C3D8RT) mesh elements with reduced integration and hourglass control. The mechanical loading step was carried out from which the thermal step propagates. The result obtained indicate that the stress induced in the work piece was insufficient to cause effective shearing and material removal while the magnitude of the average heat flux was found to be sufficient. The maximum values of the cutting conditions obtained include stress (9.051 MPa), average heat flux (2.102 × 109 𝑤𝑤/𝑚𝑚2), cutting speed (7700 m/min or 128.359 m/s), strain (3.12 × 10−13), resultant force (2.147 × 1010𝑁𝑁) and nodal temperature (25oC). It is envisaged that the findings of this work will assist machinist in effective milling operation of stainless steel AISI 301.
Description
15th CIRP Conference on Intelligent Computation in Manufacturing Engineering.
Date
2022-07-14
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Publisher
Elsevier
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Keywords
CAD, Milling operation, Modelling, Simulation, Stainless steel