Finite element machining simulations of aerospace materials

• Published in: Materials today : proceedings Vol. 46; pp. 991 - 998
• Main Authors: Dodla, Srihari, Kirpalani Idnani, Kushal J., Katyal, Arjun
• Format: Journal Article
• Language: English
• Published: Elsevier Ltd 2021
• Subjects: Arbitrary Lagrangian-Eulerian (ALE); Chips formation; Conventional; Cutting force; UVA; UVA; Chips formation; Arbitrary Lagrangian-Eulerian (ALE); Conventional; Cutting force
• ISSN: 2214-7853; 2214-7853
• DOI: 10.1016/j.matpr.2021.01.136

In this study, a comparison between the conventional machining and ultrasonic vibration-assisted (UVA) machining of aerospace materials has been addressed. The aerospace materials that have been taken into consideration for this study are aluminium alloys, titanium alloys, and Inconel-718. Aluminium alloys are one of the commonly used materials due to its lightweight and corrosion-resistant properties. Titanium alloys are making more and more presence in the aerospace industries for its high-temperature performance. Inconel-718 is a Nickel-based alloy and an aerospace material that makes it as one of the materials in demand. Titanium alloys and Nickel-based alloys are hard and hence difficult to machine. The numerical analysis for both the machining method will consist of the analysis of forces on the cutting tool, thermal effects, and the morphology of the chip formation. The numerical results are compared with experiments. Usage of dynamic, temperature - displacement, explicit solver along with Johnson Cook parameters to simulate machining is suggested for its close resemblance with real simulation. Based on the results, it is found that the UVA is much more effective method of machining as compared to conventional machining. UVA machining reduces the temperature in the contact zone, machining forces, and the machining-induced effects like the development of work-hardened layer.