3D FEM simulation of helical milling hole process for titanium alloy Ti-6Al-4V

As an emerging hole-machining methodology, helical milling process has become increasingly popular in aeromaterials manufacturing research, especially in areas of aircraft structural parts, dies, and molds manufacturing. Helical milling process is highly demanding due to its complex tool geometry and the progressive material failure on the workpiece. This paper outlines the development of a 3D finite element model for helical milling hole of titanium alloy Ti-6Al-4V using commercial FE code ABAQUS/Explicit. The proposed model simulates the helical milling hole process by taking into account the damage initiation and evolution in the workpiece material. A contact model at the interface between end-mill bit and workpiece has been established and the process parameters specified. Furthermore, a simulation procedure is proposed to simulate different cutting processes with the same failure parameters. With this finite element model, a series of FEAs for machined titanium alloy have been carried out and results compared with laboratory experimental data. The effects of machining parameters on helical milling have been elucidated, and the capability and advantage of FE simulation on helical milling process have been well presented.

Effect of web holes on web crippling strength of cold-formed steel channel sections under end-one-flange loading condition – Part I: Tests and finite element analysis

Web openings could be used in cold-formed steel beam members, such as wall studs or floor joints, to facilitate ease of services in buildings. In this paper, a combination of tests and non-linear finite element analyses is used to investigate the effect of such holes on web crippling under end-one-flange (EOF) loading condition; the cases of both flanges fastened and unfastened to the bearing plates are considered. The results of 74 web crippling tests are presented, with 22 tests conducted on channel sections without web openings and 52 tests conducted on channel sections with web openings. In the case of the tests with web openings, the hole was either located centred above the bearing plates or having a horizontal clear distance to the near edge of the bearing plates. A good agreement between the tests and finite element analyses was obtained in term of both strength and failure modes.