Cutting Tool Geometry and Parameters Effects on the Force and Temperature in Turning Steel 1040 Using Finite Element Analysis

Abstract

In recent years, applications have been proven finite-element method (FEM) in metal-cutting operations to be effective process in the study of cutting and chip formation. In this study, the simulation results are useful for both researchers and machine tool manufacturers for improving the design of cutting parameters. Finite-element analysis (FEA) that used in this study of simulation the cutting parameters and tool geometries effects on the force and temperature in turning AISI 1040. The simulation parameters that used in this study are cutting speed (75 - 300 m/min),feed rate (0.2 mm/rev), cut depth (0.75-1.5 mm), and rake angle (0-20 °). The results of cutting forces were (240 – 520 N), the temperature were (300-420 °C), and the heat rate (14202.3-83772.8 W/mm3) on the cutting edge. The simulation process also show that the increase of cutting speed leads to decrease in the cutting forces, while it has increasing in temperature, and heat rate. Also, the results show that the increase of cutting depth associated increase the cutting force only.