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FAILURE MECHANISM ANALYSIS OF TURNING PROCESS FOR CERAMIC MATERIALS

MOHAN SAI BEESABATHUNI

19670603

A report submitted for

300597 Master Project 1

in partial fulfillment of the requirements for the degree of

Master of Engineering

Supervisor: Prof. Richard Yang

School of Computing, Engineering and Mathematics

Western Sydney University

ABSTRACT

The engineering applications are uses worldwide in leading manufacturing, research and production sector. There are numbers of research done in order to enhance the productivity, machining operation and make more easy operation as per customer demand and requirement. The similar concept and theory uses for this project and study about the “failure mechanism analysis of turning process for ceramic based materials”. In this case, the mechanical analysis of turning process for ceramic material performs by using CAD and CAE application. The sample structure of turning machine process has been develop using solid works software and performs finite element analysis in order to test the feasibility of sample element and machine tool, the static structural analysis has been perform. The project provides the numerical analysis in order to obtain the mechanical parameters and properties i.e. force, velocity etc. The characteristics are uses to perform finite element analysis and significant results of the simulation. There are two simulation perform by considering different condition. In first case, the dynamic force situations assign and perform finite element analysis in order to obtain behaviour of sample element. Further, the force analysis perform to test the feasibility of the sample element by considering actual working condition of turning process.

Table of Contents

ABSTRACT i

ACKNOWLEDGMENTS ii

LIST OF TABLES iv

LIST OF FIGURES v

CHAPTER I: INTRODUCTION 1

1.1 Aim 1

1.2 objectives 2

CHAPTER II: LITERATURE REVIEW 3

2.1 Fracture Mechanism 3

2.2 Development of Suitable Tool Material 4

2.3 Cause to Failure 6

2.4 Susceptibility of Certain Ductile Materials to Brittle Fracture 7

2.5 Tool wears evolution and damage accumulation 8

2.6 Ceramic cutting tool materials 12

2.7 Aluminum oxide type ceramics 13

CHAPTER III: METHODOLOGY 15

3.1 Introduction 15

3.2 Design: Solid works 15

3.3 Material selection for the process 19

3.4 Finite Element Analysis of Turing process for ceramic materials 20

3.5 Static structural Analysis of Turning Process 21

3.6 Mathematic Model of turning machine: 24

3.7 Finite Element Analysis: Force Analysis 25

CHAPTER IV: PRELIMINARY RESULTS 27

4.1 Results and discussion: Turning machine operation for ceramic materials 27

4.2 Force Analysis: 29

CHAPTER V: SUMAMRY AND RESEARCH PLAN 32

5.1 Summery: 32

5.2 Research plan 32

REFERENCES 34

LIST OF TABLES

Table 3‑1 dimensional parameters of the turning machine 23

Table 3‑2 Selected technological parameters 23

LIST OF FIGURES

Figure 2‑1 Tool Wear in Hard Turning for CBN and Mixed Ceramic Tool Inserts 5

Figure 2‑2 Flank wear of the tools vs. impact number. 8

Figure 2‑3 SEM images of the worn tools tested at f ¼ 0.1 mm/r and ap ¼ 0.2 mm, (a) n ¼ 113 m/min, (b) n ¼ 204 m/min. 9

Figure 3‑1 Solidworks Model of Rectangular plate 15

Figure 3‑2 Machine Tool 15

Figure 3‑3 Assembly of turning machine operation 16

Figure 3‑4 200 x 100 x 10 mm Rectangular sample plate 16

Figure 3‑5 Machine Tool 17

Figure 3‑6 Assembly for turning process 17

Figure 3‑7 Ceramic material assigns to sample machine element 20

Figure 3‑8 Geometry of turning process 21

Figure 3‑9 Boundary and loading condition of turning machine 21

Figure 3‑10 Meshing 22

Figure 3‑11 Boundary and loading condition 24

Figure 3‑12 Meshing 24

Figure 4‑1 Deformation 26

Figure 4‑2 Von-misses stress 27

Figure 4‑3 Elastic strain 28

Figure 4‑4 Deformation 28

Figure 4‑5 Von-misses Stress 29

Figure 4‑6 Elastic strain of ceramic based material 30

1. : INTRODUCTION

The fracture mechanics is the special branch of mechanical engineering which concern for the crack propagation in the materials. The methodology uses for the analysis of the solid mechanics in order to obtain the drive force by considering the crack and those experimental studies categories for solid mechanics to characterize the material’s resistance to the fracture. By considering the modern science, the fracture mechanism is important tools which uses for enhance the overall performance of the machine component. That applied in the physics of stress and strain behavior of the materials by considering fundamental theories of elasticity and plasticity, by considering the microscopic behavior of the materials of the machine assembly. In this case, the Fractrography is widely uses with fracture mechanics in order to considering the cause of failure and ensure the theoretical failure predictions by considering real life failures.

In this project, there is discussion about the failure mechanism analysis of the turning process for ceramic materials. The turning is the basic mechanical manufacturing process which uses to reduce size, shape and geometrical shape of the sample element. It is notice that the project report is discussed for the ceramic based materials. The ceramic material properties is differ from the conventional materials, alloys etc. therefore, the machine operation is different from the conventional manufacturing process. The project report provides the detail overview using solidworks application and performs numerical analysis through finite element analysis approach. The result indicates the significant aspect of the turning machine by using ceramic based materials.

1. Aim

To research and study about the failure mechanism analysis of turning process for ceramic based material.

In this report, the CAD and CAE approach uses in order to design and analysis of turning process for ceramic based material. The sample machine component and tool geometry prepared by referring conventional machine tool which uses for industrial application. The machine tool is prepared and performs simulation in order to obtain feasibility by considering actual working condition. The simulation perform through finite element analysis procedure in order to obtain design significance and performance parameter output.

1. 1.2 objectives

• To study about the fracture mechanism analysis and significance for mechanical department.
• To study and research for conventional turning process for the different material includes ceramic based material.
• To study about the CAD technology usefulness for research and application. To perform static structural analysis for testing the mechanical parameters such as strength, rigidity and design criteria.
• To derive mathematical model and numerical analysis of turning process for ceramic material operation.

2. : LITERATURE REVIEW
   1. 2.1 Fracture Mechanism

To understand the different drawbacks of the different tools of cutting and to remove such drawbacks, a review of literature was done. The detailed idea of such papers is shown here. In the research works of Shackelford et al.,(2016), it is seen that an FEM examination has been done for the design of optimal end mill cutters by means of verification of the forces of cutting tool and it emphasizes for milling of the alloy of Titanium 6Al-4V. The various parameters for cutting tool and designing of end mill of various sizes are done based on the least forces of tool. The end mill 3D CAD model is designed and utilised for the Method of Finite Element so that the verification of the force of cutting for milling Ti-6Al-4V can be understood. The Ti-6Al-4V is taken as one piece of work material and the cutting tool gives forces, stress, concentration is strained and tool wear and the voltage of such tool of various geometrical dimensions are given on it. In the end, the various theoretical outputs are made comparison and the outlook of the tool for cutting of various sizes is examined (Denry,. and Kuhn, 2016).The approach takes into account to enhance the quality of the surface of the machine and the life of the tool along with the impact of different parameters.

In the opinion of Deepthi et al .,(2016), one of the most important issues that is faced during preparation process is that end milling is effected in a negative manner. The researchers are analyzing the problems regarding the series of the end milling process. The different issues that occur in the end milling process are mainly focused on the FMEA. The issues are included in the risk priority that helps in developing effective strategy to mitigate risk. In the case of the Rotation per minutes, it should be adjusted according to the requirement. The RPM should be adjusted preventive measures should be done in an efficient way.

According to the opinion of Alves, Baptista, and Marques, (2016), there is advancement of the designing methods that helps to fine tuning the ceramic product in an efficient way. The cutting of the ceramics materials is accompanied by the high temperature in the market that helps to develop the cutting process. It has been seen that one of the major alternative process of cutting is present which Colling system is. First the heat is applied to the material and then it is cooled and integration is done if there is requirement to develop the products in a special way. One of the most important components is the use of the cutting method to achieve the fine-tuning and micro geometrical structure without harming the integrity of the process. The thin layer is modified in an effective manner by developing the outer edge of the material in an efficient way. The edge radius is very important as it helps to provide the main strength of the material in an effective manner. In the opinion of Huo et al., (2016), when the fine-tuning is done it helps to improve the roughness component. Moreover, identifiable K factor is important to develop to the optimum values in an efficient way. It has been that Monolithic-cutting tool is used as optimum value enhancement.

It is seen according to Wang, (2016), cutting edge tools the materials are composed with 70 % of the Aluminum trioxide. Cold process is done that includes the d2 AISI to improve the hardness coefficient. It has been observed the appropriate cutting edge helps in reducing roughness of the materials by at least 0.8 cm. cylindrical gridding option helps in decreasing roughness.

1. 2.2 Development of Suitable Tool Material

One of the most important factors is the innovative technology of ceramics material that helps to enhance the hardness of the products in the market. It has been seen that innovative technology helps in developing the hardness of the internal crystalline structure of the materials. The chemically inert structure is used to enhance the hardness of the material. The study includes poly crystalline hardness that includes the three different steels HSS steel and gross fracture and cutting edge technologies. CBN tool is one of the most effective tools used in ceramics technology. The CBN point is used to fine-tune the product in an effective and efficient way.

According to the opinion of Tian et al.,(2016), the high-speed steel should be used products are used effectively including the CBN mechanism that developed the integrity of the ceramic materials in an effective way. However, it is seen, that manufacturing cost in the CBM technology increases the high-end cost of the materials in an effective way. If compared with the older tools the CBM tools have better efficiency as it helps to develop the process of CBM in an effective manner. The HSS steel also performs in a better way to develop the tools in an efficient manner (Raffaella, Roberto, and Antonio, 2016).

Figure 2‑1 Tool Wear in Hard Turning for CBN and Mixed Ceramic Tool Inserts

The Microstructure, gain size, bonding material are considered as CBN Contents which result in the effective or ineffective performances of CBN Tools. Tools of CBN can be classified into mainly two types. In the first type of CBN, there is more than 90% of CBN Content and thus the gains of CBN in this case are bonded by is bonded directly by metallic binders or themselves (Chen, 2015). The next type in this case only contains CBN Content of 50% – 70%. Thus, it is a very lower number than the first type. In this particular case, the gains of CBN are bound by TiN or TiC. These are all ceramic binders.

In CBN Inserts there are different types of features which must be taken into account. First of all, the solid CBN Inserts have very low ferrite-containing. It is less than 10% in this case. For this particular insert, finishing as well as large scale margin roughing is up to the mark. In terms of composite inserts related with CBN, they have a very effective resistance to wear. CBN inserts of this type have carbide substrate which is better than others. The hardness in this case is more than HRC45 (Boccaccini, 2015). The margin in this case is also very small. Mosaic CBN insets are less costly than composite tools and thus they are used for lowering costs. In this case there are many cutting edges in just one side. This has a top surface which is sintered on carbide substrate which is cemented.

1. 2.3 Cause to Failure

Different steps lead up to a case where any engineered device fails to perform. Engineered devices are generally consisting of particular properties of components and thus it is important that the failures of the components are focused on. The discussion in this case will contain the mechanisms which are found in the natural environment and which will affect the properties in an adverse manner. The steps that were discussed in this case are as follows –

• Reason
• Less protection from the mechanism related with failure (less prevention)
• The activities of failure mechanisms
• Deterioration that is measurable
• Defect – Chances of failing (defects to the point where the machine is unable to act as per the performance levels which are expected)
• The mode of failure
• Failing

It might be possible that viewers in this case can think that distinctions are made in between steps that are only a bit different. The students will understand that the differences in this case are very valuable in terms of understanding the reasons or aspects of Human Invention failing or human inventions being a success.

The “cause” in this case can be regarded as an activity which led to the necessary amount of prevention not being used. It is very necessary that the actual activity and the cause are differentiated. For an example, if a particular activity is of an organization is not funded by the corporate officer, and then there will be many cases where corrosion can be witnessed (Fang, 2015). If the activity in the example was painting the walls of the office, then the painter would not be the reason of failure, the main reason will be the failure is in this case the decision making of the officer. The objective of distinction therefore is to understand about the exact cause of the failure.

The following steps must be kept in mind while understanding about the causes related with a particular failure. The first step in this case is the less protection and the next step is the work of Failure Mechanism (Ahmad, 2015). The difference in between lack of prevention and the failure mechanism at work is necessary for the understanding of the following examples –

• Corrosion results in production of metal oxides which can be called as rust.
• Erosion in this case can result in debris that will come due to the thinning process. Lubricants in this case are used. Oil analysis is also done so that the Erosion can be avoided.
• Another factor is physical presence due to the factor of Overload. Supporting elements are bended in this process.

1. 2.4 Susceptibility of Certain Ductile Materials to Brittle Fracture

A notch-sensitive material exhibit the nature of transition from ductile to brittle, which indicates that material fractures are extremely depended on deformation changes, temperature and stress distribution and nature. For instance, Woodward and Hill (2017) argued that carbon steel, plastic materials and some other materials are highly notch-sensitive. At the transition temperature, these materials exhibit a sharp change from ductile nature to brittle nature. This has been expressed in the figure.

In the figure, it has been shown that in a narrow range of temperature, various plastic materials and several others show a reduction of the elongation that indicates the behaviour of brittleness. Furthermore, Rice (2017) argued that in the figure, the same properties have been shown in case for Steels that have different carbon contents. However, in this case, the energy required for creating a specific size of fracture is measured instead of elongation.

The ceramic material based on Al₂O₃ is used quite frequently, and it is also seen that these materials exhibit chemical stability, heat and wear resistance, and high level of hardness. This is why it is used for evaluating the applications of hardened steel. Baluta et al. (2017) argued that this allows the measurements of the mechanisms of failure for ceramic materials with the composition of AL2O3-(W, Ti)C. The process involves damage mechanics using hardened steel with specification of AISI 1045. The steps of the process include RVE or representative volume element, where thermal and mechanical loads are used for induction of tri-axial stress through micromechanics technology. Using this model, Guo et al. (2017) argued that the critical and initial damage can be evaluated using models created by mathematical calculations, and the turning process of intermittent stages can be evaluated using the material stress and damage. This is used to evaluate the clearance angle, tool rake and exit angle is determined using one cutting cycle process within a process of turning that is intermittent. This allows the measurement of MDES or maximum damage equivalent stress, and it can be used in order to measure the geometric design and materials design related information of the tools for cutting ceramic materials.

1. 2.5 Tool wears evolution and damage accumulation

The process of evolution for tool wear is seen in the figure, and it explains the process of tests of turning in the intermittent stages. Furthermore, according to Chen et al. (2017), it has been seen that the number of impacts in certain intervals is remained at an equal level for the flank wears in the various tools. These wears and tears are usually taken as the results and consequences of the accumulation of the damages on the material of the tool.

Figure 2‑2 Flank wear of the tools vs. impact number.

The tools made of ceramic materials accumulate damages at the zone of cutting, and it does not trigger any changes in the wears of the flank. Furthermore, some local areas can experience damages at levels that are considered as critical, and it results in a separation of tool materials. Liu et al. (2017) argued that this may suddenly increase the wears in flank, and it also reduces the time during which the other areas experience accumulation of damage and fractures in various other regions. The wear value of flanks enhances the number of impacts in various intervals, and this process of evolution of tool wear results in failure of tool, which is final. The figure shows that the tools have been examined at high or low speed of cutting, and fracture usually dominates the surfaces that have been failed.

Figure 2‑3 SEM images of the worn tools tested at f ¼ 0.1 mm/r and ap ¼ 0.2 mm, (a) n ¼ 113 m/min, (b) n ¼ 204 m/min.

The figure shows that the fracture has been resulted from the joint impact of thermal and mechanical stress that is created from the intermittent process of cutting. Here, the tools made of ceramic materials are shown, where their surface fractures are magnified using the SEM system of imaging that is typical. Furthermore, Jõgi et al. (2017) argued that the pull-outs of the grains occurs due to the fractures at an intergranular level, and the voids generated due to the fracture. Thus, it can be understood that accumulation of damage in the tools is resulted from the loads that are external, and the expansions of the microcracks is also a reason behind this.

The evolution of the wear of the cutting tools made from ceramic materials display the properties of the accumulation of damage and sudden fractures for the steel with AISI 1045 specifications with turning process that is intermittent. According to Doleker, Ahlatci and Karaoglanli (2017), the microcrack growth results in the accumulation of damage at the boundary of grains. Furthermore, the failures of the tool mechanisms result in damages in the materials of tools.

On the other hand, the hard tuning of the tools made with ceramic materials has many more advantages when compared to the common and traditional system of grindings. From instance, this results in a reduction in the requirements of cutting fluids, higher accuracy of machining process, greater productivity and much lesser cost. However, Kähäri et al. (2017) argued that the turning process of steel in hardened state is often seen in the case of huge fractures of ceramic tools, and thus it bring in a requirement to identify the development of the various aspects regarding the machinability characteristics, such as wear of tools and forces of cutting. In order to evaluate the various mechanisms of failure in the turning of intermittent stages of Al2O3-TiC tools of ceramic materials and 20CRMnTi alloy of steel. Furthermore, the various stages of wears of tool is analysed using the ANOVA process, which utilises the variance, whereas the parameters of cutting affecting the forces of cutting is evaluated using the method of Taguchi. The wear on the tools is increased by the reduction of forces of cutting affecting the wear of cutting, and the cut depth leaves much less impacts on the forces of cutting. Moreover, Ghazanfari et al. (2017) argued that when the amount of fractures in various conditions of cutting is evaluated, it shows that the even when the speed of cutting is different for different paths of propagations, the mechanisms for the cracks due to fatigue can be analysed. Furthermore, it shows that while the depth of the propagation of the crack is directly affected by the thermal stress, the area of fracture for the tool is directly affected by the mechanical stress.

In case of the machining process that is hard and precise, it is generally used for the scientific researches, parts of automobiles, manufacturing process of molds and dies, and many others. There are various positive aspects of machining with the hard process, such as low roughness of surface, high flexibility of the process, and reduced duration of cycle for the cutting process. On the contrary, there are various different disadvantages of the machining with the hard process, such as increased stress of residual and cutting activity, requirement of tough tools for machining, and greater cost for tooling process. Rahaman (2017) argued that the stress level of the ceramic tools has to be reduced to achieve hard finish tuning in the tools for cutting ceramics. Thus, this article discusses the effects of parameters of cutting of the steel of specification AISI H13 that have been hardened using hot working process on its stresses of cutting. These forces of cutting have been measured using tests on tuning with serial finish. Here, FEM or finite element model is used in order to determine the stresses of cutting for steel of AISI H13 specification while inserting grade 650 of ceramic, which obtains the required result.

This particular research aims to evaluate the mechanisms of fracture and failure modes for the ceramic product with the composition specification of Al2O3-(W, Ti)C when exposed to the intermittent turning process of the hardened steel with the specification of 20CrMnTi. The transient temperatures and the forces of cutting is measured during the complete cycle of life, and in this process, the surface failures is measured using electron scanner microscope and optical digital microscope. From the experimental results, it becomes obvious that the forces of cutting causes an increase in the failure of the tools. Rezakazemi et al. (2017) argued that the process of turning in intermittent stage causes micro-chipping and other forms of wears in the tools made of ceramics, which is caused by thermal and mechanical damages. Furthermore, the rate of feed and cutting is depended on the cutting temperature, where increasing temperature is caused by increased rate of cutting, and it triggers failures of fractures and failures in ceramic products. The various parameters of cutting can be categorised into four different types of fractures and mechanisms of failure. This allows the development of different applications and designs of cuttings.

The cutting tool quality is one of the most vital factors as far as the performance of the cutting is concerned, and the cutting performance can be enhanced using treatment of ceramic tool surfaces using sintering of plasma and pressing hot process. Here, Farbstein and Davies (2017) argued that the positive points and drawbacks of the various such processes and technologies have been evaluated to determine the most useful process for choosing the most efficient ceramic tool.

1. 2.6 Ceramic cutting tool materials

The various ceramic materials for cutting and machining the various super-alloys and cast iron products that can help treat the materials that are usually difficult to cut. These tools usually have mechanical properties that are quite different in nature, and they also have quite a high level of various properties such as adhesion wear, corrosion, and hardness when they are compared with the tools used for carbide cutting process. Li et al. (2017) argued that in addition to such properties, they also have various other disadvantages and advantages, which are:

• Exhibiting high level of strength while machining the materials that are difficult to cut
• Higher level of resistance against abrasive and cratering wears
• The capacity to cut materials at a high speed

The brittle nature of the various cases of ceramic ruptures has some limitations. For instance, the low level of resistance and toughness against the thermal and mechanical shock is experienced from low level of thermal conductivity. On another note, Hagedorn (2017) argued that the cycle time is reduced due to the machining speed that is quite high, and this exposes more defects. These problems have been evaluated in a number of articles, which have been discussed here.

Pressing in cool conditions results in white colour, and hot condition results in black of grey colour for ceramic materials. The while ceramic is tougher than black or grey ceramic.

The ceramic tools for cutting can be categorised in four types, which are:

• Cermet-based ceramic tools
• Sialon-based ceramic tools
• Si₃N₄-based ceramic tools
• Al₂O₃-based ceramic tools

The various major types of materials that are used for manufacturing ceramic tools are Si₃N₄ and Al₂O₃. The reason behind this is that these are the main components of the natural ceramics, and the various ceramic products display a composition for approximately 30% of titanium carbide and the 70% of ceramic materials. Zhao et al. (2017) argued that the ceramic alloys are used in conjunction with the Oxides of Zirconium, and a 15% segment of the total ceramic product shows strong bonding of inter-atomic and ionic nature.

1. 2.7 Aluminum oxide type ceramics

The ceramic products of various natures are used as per the physical properties of the components. For instance, the Al₂O₃ materials exhibit high level of hardness and various other unique properties. Lund et al. (2017) argued that the lack of damage and brittleness reduces the tolerance of the ceramic materials in terms of their chemical and mechanical properties, especially in high temperatures. Such ceramic products exhibit reduced chemical reactivity, increased hardness and increased resistance against wears.

The commercial ceramic tools for cutting purpose are mainly in the group of ceramic products with carboxide components, and it consists of approximately 40% to 30% of carboxide materials. Furthermore, the material hardness is also increased at a temperature of upto approximately 800⁰C. According to Arcaro et al. (2017), the Titanium ceramic materials are usually better than conventional ceramic materials much more, so that their conductivity and expansion due to the increase in temperature is much lesser than conventional ceramic products. This allows a much better cutting performance for the Ti ceramic tools, such as cut depth and rate of feed, speed of cut and many more.

3. : METHODOLOGY
   1. 3.1 Introduction

In mechanical engineering branch, the product design mainly by considering two aspect and design based on two approaches i.e. strength and rigidity criteria. As per the theory of engineering, the product design prepare by using mainly three methodology i.e. Fundamental mechanical engineering techniques are uses the theory of machine and failure criteria for preparing machine component. From the study and past research, the fundamental machine design is useful for standard machine component design and operation i.e. shaft, gear, bearing, pulley, rod, beam, truss etc. which useful for motion transmission. Therefore, the fundamental machine design technique is only applicable for those product which standard and useful for motion transmission and power transmission. Apart from this, there are another two techniques which useful by considering product design i.e. software methodology and experimental approach. In this project, the software methodology uses for design and analysis of machine component usefulness. The product design is prepared by using CAD application and performs simulation using CAE software technique.

In order to make realistic manufacturing approach, there are simple machine tool and sample geometry assembly prepared using solid works software. In order to test the machine tool that it able to perform manufacturing operation such as turning operation, the finite element analysis methodology uses which provides the significant result that indicate the machine tool is able to perform turning operation or not. The following is provides complete procedure of solid modelling and finite element analysis of turning process for ceramic based material.

1. 3.2 Design: Solid works

In this case, the simple geometry has been prepared which contains the sample element and machine tools. The following is provides the manufacturing drawing of the sample element and machine tool which prepared by using solid works software. The following is provides the solid works model, assembly and manufacturing drawing.

Figure 3‑4 Solidworks Model of Rectangular plate

Figure 3‑5 Machine Tool

Figure 3‑6 Assembly of turning machine operation

Figure 3‑7 200 x 100 x 10 mm Rectangular sample plate

Figure 3‑8 Machine Tool

Figure 3‑9 Assembly for turning process

The above diagram provides the systematic machine design approach which uses and implement for research and industrial purpose. As provide in above diagrams, the initial step of the design engineer is to prepare solid work model by using past reference drawing or machine component. The next operation is to assemble that component such as way that complete assembly require as per product specification and customer requirement. Lastly, the manufacturing drawings are extracting to make that able to understand for production team and department for actual production using conventional manufacturing process such as turning, grinding, machining, hobbing etc.

1. 3.3 Material selection for the process

The material selection is important step for any product or machine design. The material selection is the first step in the designing process of any physical object. In this situation, the aim of the material selection is to reduce overall cost of the product by considering performance objectives. Therefore, it is essential that the design engineer have sufficient knowledge for the material properties and their behaviour by considering working situation. Some of the important aspects and characteristics of materials are durability, strength, flexibility, heat resistance, corrosion, weld ability, machinability, electric conductivity and hardness.

The material selection based on the specific criteria and considering product application, usefulness, thermal and mechanical properties. Similarly, in this case, the material selection based on desirable functional output and external applied load, pressure and force quantities.

In this project, the turning process is performing for ceramic material metal removing. It is notice that the conventional turning machine are perform for conventional material removing through lath machine, CNC , VMC and HMC automatic machine operation. That machine is suitable for the steel, cast iron, wrong steel, stainless steel and alloy steel machine operation. The project motive is to use ceramic based material for turning operation. Therefore, the material selection is based on that product feature, characteristics and mechanical properties as well.

From the research and study, it observes that the “high strength steel” material is suitable for the machine tool. Therefore, in this case high strength steel material is uses for turning operation.

In order to test the feasibility of machine tool, it is require to perform finite element analysis and simulation which provides the significance result about the material selection and suggest that the operation is acceptable or not by considering practical aspect. The following is provides the finite element analysis procedure of turning process perform by using ANSYS application.

1. 3.4 Finite Element Analysis of Turing process for ceramic materials

There is systematic method which applicable for any type of FEA analysis whether static structural, thermal, dynamic analysis, transient analysis, optimization etc. the following provides the brief of finite element analysis procedure uses for turning operation.

1. Prepare CAD geometry using solidworks software and save as CAD model which applicable for CAD and CAE software. In this case, the turning machine model saves in “parasolid” file and import into ANSYS software.
2. There are number of analysis provides in the ANSYS software, select desirable analysis and drag into working environment.
3. Select and assign engineering material from the database and create database for the material assigning.
4. Import the CAD geometry into designer module.

Boundary and loading condition:

1. Assign material to suitable machine component.
2. Assign boundary and loading condition to the machine assembly by considering actual working condition and realistic situation of the machine assembly.
3. Mesh operation to discritize the entire assembly into finite size.
4. Plot result

Result discussion

1. Plot contour result and discuss significance of those results.
2. The static structural analysis provides deformation, stress and strain contour graphs

The following is provides the complete procedure of static structural finite element analysis procedure perform for turning process.

1. 3.5 Static structural Analysis of Turning Process

CAD model preparation:

This is first step for any analysis where the designer prepares the sample CAD model as per objective and requires functional output. In this case, the sample ceramic based machine element prepared where the High strength tool allows performing turning operation as considering actual working condition. The next step is to assign mechanical material properties sample element and tool material. It is notice that the material properties library has been provide in solidworks and ANSYS as well. The designer is eligible to choose correct material from computer library. In this case, the materials are selected from ANSYS library as shown in following diagram.

Figure 3‑10 Ceramic material assigns to sample machine element

As shown in above diagram, the sample element has been assigning the ceramic based material with mechanical properties. The next operation is import the geometry into designer module in order to provide the realistic scenario of working condition. The following is providing the diagram of geometry import into ANSYS designer module.

Figure 3‑11 Geometry of turning process

The above diagram provides the actual working situation of sample element which is copied from original operation of turning machine. The next step is to import the assembly into “designer module” and allows assign the constraint. The following diagram provides the boundary and loading condition of turning machine operation.

Figure 3‑12 Boundary and loading condition of turning machine

The above diagram provides the boundary and loading condition of the turning machine by considering actual working of the turning operation. In this case, the sample element which needs to remove material or perform turning operation, that kept fixed in two direction i.e. horizontal and vertical direction. That means the sample element is not displacing in any direction apart from z-direction. At the same time, for turning operation, allows moving in horizontal direction in order to remove material. In this case, the “High strength steel” machine tools allows to move in horizontal direction with 180mm displacement which highlight in “yellow colour “. It is notice that the backside or front side of the sample machine element is kept fixed in order to grip their position and didn’t allows to move in any direction. That will able to perform turning operation in order to remove material from the sample element. As assigning boundary and loading condition, the next task and step is to assign or mesh the complete assembly as provided in following figure.

Figure 3‑13 Meshing

As shown in above figure, the mesh operation performs in order to discritize the entire segment into finite size and element. The meshing is essential the basic requirement for any finite element analysis procedure where the entire machine component has been discritize or separate into small size. In this case, the default “tetragonal” mesh has performed in order to divide entire machine structure into finite size. The accuracy and overall performance of machine structure is depending on the mesh operation. The design engineer can revise the design by obtaining contour result and find the significant result from the simulation. The next step is to plot result and provide significance characteristics of FE analysis.

1. 3.6 Mathematic Model of turning machine:

The three dimension turning machine is prepare for removing material and subjected to the analysis. The design of turning machine took into the account for the lowest weight of the machine. The following is provides the basic dimensions of turning machine.

Table 3‑1 dimensional parameters of the turning machine

Sample element dimension	Value	Units	Travel (axes )	Value	Units
Length	200	mm	X	180	mm
Height	100	mm	None	0
Width	10	mm	None	0	0

Table 3‑2 Selected technological parameters

Parameter	Nomenclature	Value	Units
Tool dimension	D	5	mm
Numbers of tool flute		1
Cutting depth		2	mm
Cutting width		5	mm
Cutting speed
Feed rate		0.1
Angle of heel edge		20	Degree
Specific cutting resistance			Mpa
Wear resistance		1.5	Mpa

Cutting resistance:

Cutting force:

Calculation of radial force:

1. 3.7 Finite Element Analysis: Force Analysis

By using above value, let us perform finite element analysis in order to test the feasibility of sample ceramic based material. The following is provides the procedure of static structural finite element analysis. The procedure of finite element analysis is similar as discussed in earlier phase.

1. Import CAD geometry and assign material as perform in previous case of simulation.
2. Assign boundary and loading condition. Perform mesh operation in order to discritize the segment into finite size.

Figure 3‑14 Boundary and loading condition	Figure 3‑15 Meshing

The above figure provides the constraint in order to perform the finite element analysis and obtain the strength and feasibility under static condition. The force magnitude applied in tangent direction by considering force of “machine tool”. The force magnitude assign as obtain in previous “Numerical analysis”. The simulation result ensure that the force is sufficient or not for removing material. The result obtain from the simulation is provided in next section.

4. CHAPTER IV: PRELIMINARY RESULTS
   1. 4.1 Results and discussion: Turning machine operation for ceramic materials

As assigning boundary and loading condition, the next step is to plot results which give the significant result about the turning machine. The static structural analysis provides mainly key parameters such as deformation, von-misses stress, elastic strain etc. The following is provides results.

Deformation:

Figure 4‑16 Deformation

The above figure provides result obtain from the static structural analysis and usefulness while designing and select material accordingly. It is notice that any machine components are design based on mainly two machine design theory i.e. strength and rigidity based. That means, the machine component have sufficient strength that it may not deform or change the geometrical condition as applied external force, pressure and load over the body. The current design is based on rigidity of material; therefore it is essential to ensure the strength of material. In this case, the maximum deformation occurs over the top surface of the sample element. That means, the machine tool is able to deform and obtain desirable shape over the span of the sample machine structure.

Von-misses stress

Figure 4‑17 Von-misses stress

The above figure provides the contour graph of the turning machine which provides the range of stress and induces over the surface of sample element. In the above diagram, the maximum stress induces over the surface of sample element and machine tool contact point which highlighted in RED colour. It is notice that the maximum stress over when turning operation start, apart from this, the entire structure is safe by considering loading and boundary condition. The maximum value of stress induce as which is considerable less compare to ultimate tensile stress of machine assembly and yield stress of sample element. Therefore, the machine tool is not broke out due to friction and force between mating parts.

Figure 4‑18 Elastic strain

As shown in above diagram, the maximum strain induce as which is marginally less, the design engineer can refuse that stress.

1. 4.2 Force Analysis:

The following is provides the result which obtain through simulation of the sample ceramic element by assigning constraint, boundary condition etc. the following is provides the deformation, von-misses stress and elastic strain.

Figure 4‑19 Deformation

As shown in above figure, the deformation obtained is considerable less but it indicates the machine tool allows changing the geometry by external applied force. This is static situation of the machine element and tool where the initial force requires deforming or changing the geometry. The maximum deformation occurs over the surface i.e. which is consideration. This indicate the machine tool require dynamic or motion element i.e. Velocity of the machine tool. If applied force with high velocity, the turning operation can perform.

The above provides the evidence that the machine component require minimum force to remove material.

Figure 4‑20 Von-misses Stress

The above figure provides the significance evidence that the ceramic material is safe in static condition before dynamic force was not applied. As shown in above figure, the maximum stress observes as which is lesser than the ultimate yielding stress of the sample element. The ceramic base sample is safe in static condition.

Figure 4‑21 Elastic strain of ceramic based material

The above diagram provides the significant evidence for the ceramic based material. This is safe result as observe considerable less strain.

5. CHAPTER V: SUMAMRY AND RESEARCH PLAN
   1. 5.1 Summery:

The project report is discussed about the fracture mechanism analysis of the turning process for the ceramic based material. It is notice that there are three different contexts which merge for the common goal. In this case, the fracture mechanism is specific machine design content where the material properties and behaviour play key role for the performance point of view. Further, the turning process is conventional machine operation which perform manual and automatic machine operation in order to remove material, but it generally observe for steel, cast iron, wrong iron, stainless steel and steel based material. The ceramic based material has different mechanical properties compare to conventional material. It is brittle material and difficult to perform machine operation. Therefore, it is require designing and performing analysis for obtaining mechanical parameters such as force, pressure, degree of freedom, failure criteria etc. therefore, the research project discuss the numerical analysis in order to obtain force quantity and perform static structural analysis to obtain displacement and displacement quantity. The displacement quantity indicates the machine tool allows travelling throughout the path of sample element and allows removing material. Similarly, the force analysis perform over the ceramic based material to obtain the range of force which allows to perform turning operation and material remove through operation.

1. 5.2 Research plan

The finite element analysis is performing by considering two different conditions. It is obvious that the ceramic sample element may vibrate due to wear and tear between mating parts. Therefore, the model analysis needs to perform in order to obtain the range of vibration, mode shape and frequency.

• When consider the turning process, due to wear and tear, the heat generate between the mating parts. In obtain the behaviour of turning machine tool and sample element, it is require to perform thermal analysis which gives the magnitude and range of temperature, heat flux.
• The sample element and machine too design is arbitrarily, that can reduce size, shape and change the geometrical shape of the sample by performing optimization operation.

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