Manufacturing Technology Today

Haider Nasreen ¹, S. Rajendra Boopathy ², M. Murugan ¹, S. Zubaida Kathoon Bee ¹

Affiliations
1 Dept. of Mech. Engg., B S A Crescent Engg. College, Chennai, IN
2 Dept. of Mech. Engg., College of Engg., Guindy, Chennai, IN

Abstract

This paper presents the simulation of orthogonal metal cutting of 6061 T6 Aluminium alloy using Hypermesh and LS-Dyna to study the effect of the edge radius on cutting forces and chip formation. The constitutive material model Elastic Plastic Hydrodynamic was used to model the work piece. The capability of this model to predict cutting forces, shear angle and chip curvature was investigated. Design of Experiments principle was used to study the effect of the parameters on cutting edge performance. The trends of the simulated results were in good agreement with the generally observed theoretical and experimental results. The model can also be used as a numerical tool for optimizing the edge radius. The effect of edge radius and other cutting conditions on the chip curl and the shear angle were also investigated.

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S. Senthil Kumaran ¹, S. Rajendra Boopathy ¹

Affiliations
1 College of Engg., Guindy Campus, Anna University, Chennai, IN

Abstract

Magnetic molding is a molding process which can serve as an environmental friendly casting technique and has the potential to provide a solution to many of the manufacturing and environmental problems faced by the metal casting industry today. In this work a solid pattern is used. The pattern is backed up by steel shots, which are consolidated by magnetic field. In this work castings were made with 4824, 7236, 8442 ampere turns under varying shot sizes of 40μ, 80μ and 100μ. Trials on machining were carried out on the castings obtained, under eight machining conditions by varying cutting speed, feed rate and depth of cut. The variation in the cutting force with respect to steel shot size under a constant magnetic field was determined for each of the machining conditions. The results show that shot size has strong influence on the cutting force in magnetic molding.

 

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