Publication: Análisis termomecánico mediante elementos finitos de procesos de corte ortogonal de Inconel 718
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2011
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2011-10-03
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Abstract
Este proyecto se centra en el análisis de una serie de parámetros tales como fuerza de corte, fuerza de avance, temperaturas, tensiones residuales en la superficie de la pieza mecanizada, espesor de viruta, ángulo de cizalladura, longitud de contacto viruta herramienta. Todo ello para un proceso de corte ortogonal realizado sobre el material INCONEL 718, que es un material empleado en diversas aplicaciones en el sector de la industria aeronáutica y automovilística. La información obtenida en este análisis puede ser aplicada con vistas a la mejora en distinto aspectos del mecanizado del material a tratar, tales como controlar las tensiones residuales generadas en la pieza tras su mecanizado, ya que estas juegan un papel muy importante de cara al comportamiento de la pieza fabricada. En este proyecto, se ha analizado una única geometría de herramienta con distintas condiciones de corte. Se ha utilizado un rozamiento tipo Coulomb, variando su coeficiente en dos zonas concretas, la de contacto viruta herramienta y la de la zona mecanizada herramienta. La metodología a seguir ha sido, realizar una primera pasada y a partir de aquí generar dos casos posibles a analizar. En el primer caso, tras la primera pasada se retira la herramienta, se enfría la pieza a temperatura ambiente y se miden las tensiones residuales. En el segundo caso, se retira la herramienta, se enfría el tiempo correspondiente a una revolución del cabezal de la herramienta, se sitúa la herramienta en la posición inicial y se realiza una segunda pasada para posteriormente medir las tensiones residuales. En cualquiera de los dos casos, también se extraen los parámetros de fuerzas, temperaturas, espesor de viruta, ángulo de cizalladura. Una de las partes más críticas durante la simulación es conseguir un mallado denso de 5 micrómetros en la zona de interés, que es la zona de cizalladura y la zona de contacto del material con la herramienta. ______________________________________________________________________________________________________________________
This Project focuses on the analysis of several parameters such as cut loads, temperatures, residual stress in the machining work piece surface, chip thickness, shear angle or chip-insert contact length. All of them are related to the process involved to obtain a turning in INCONEL 718 material, which is widely used for applications in aircrafts and automotive industry. Information obtained in this analysis can be applied in order to put up results in the machining of the above-mentioned material, such as to control residual stresses generated in the work piece after the machining, since they have a very important role in the machining work piece behavior. In this project, only a tool geometry has been analyzed under different cut conditions. Coulomb friction type has been used, using a different coefficient for two specific zones, chip-insert contact zone and machined face zone. The methodology to be followed has been making a pass firstly and from this moment on, two cases have been generated for their subsequent analysis. In the first case, after the first pass, the tool has been moved away, the workpiece has been cooled down to room temperature and after this, and residual stresses have been measured. In the second case, the tool has been taken away and the workpiece has been cool down the equivalent time to a revolution of the tool head, the tool has been situated in the initial position and a second pass has been analyzed so as to measure residual stresses. In both cases, loads and other parameters like temperatures, chip thickness or shear angle have been obtained. One of the most critical points during the simulation has been how to get a mesh of 5 micrometers in the shear region and the workpiece-tool contact region.
This Project focuses on the analysis of several parameters such as cut loads, temperatures, residual stress in the machining work piece surface, chip thickness, shear angle or chip-insert contact length. All of them are related to the process involved to obtain a turning in INCONEL 718 material, which is widely used for applications in aircrafts and automotive industry. Information obtained in this analysis can be applied in order to put up results in the machining of the above-mentioned material, such as to control residual stresses generated in the work piece after the machining, since they have a very important role in the machining work piece behavior. In this project, only a tool geometry has been analyzed under different cut conditions. Coulomb friction type has been used, using a different coefficient for two specific zones, chip-insert contact zone and machined face zone. The methodology to be followed has been making a pass firstly and from this moment on, two cases have been generated for their subsequent analysis. In the first case, after the first pass, the tool has been moved away, the workpiece has been cooled down to room temperature and after this, and residual stresses have been measured. In the second case, the tool has been taken away and the workpiece has been cool down the equivalent time to a revolution of the tool head, the tool has been situated in the initial position and a second pass has been analyzed so as to measure residual stresses. In both cases, loads and other parameters like temperatures, chip thickness or shear angle have been obtained. One of the most critical points during the simulation has been how to get a mesh of 5 micrometers in the shear region and the workpiece-tool contact region.
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Mecanizado, Tecnología de fabricación, Mecánica de sólidos, Método de los elementos finitos