Finite element simulation and experimental validation of the effect of tool wear on cutting forces in turning operation

Venkatesh, S.; Kumar, Tapan; Blalakumhren, A. P.; Saimurugan, M.; Marimuthu, K.

doi:10.2478/mme-2019-0040

Cited by 10 publications

(4 citation statements)

References 21 publications

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“…Researchers have used numerical simulations for studying various structural and flow phenomena in steel alloys [9]. A finite element-based model is vital in predicting resultant forces, induced residual stresses, wear and tear of a tool and temperature variation during the machining processes.…”

Section: Introductionmentioning

confidence: 99%

Finite element based model for predicting induced residual stresses and cutting forces in AISI 1020 steel alloy

Bosire

Muvengei

Mutua

et al. 2023

Materialwissenschaft Werkst

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The application of finite element models is a promising method for ensuring part quality during machining to accurately predict induced residual stresses and cutting forces. The present study applied Analysis System software to formulate a 3D model to predict induced residual stress and forces for AISI 1020 alloy. Taguchi method was applied in the design of the experiment with three levels and three factors selected: Cutting speed, feed rate and depth of cut. For validation, stresses are measured using an x-ray diffractometer from the surface to a depth of 0.6 mm in steps of 0.2 mm. The cutting forces are determined using a force dynamometer. Simulation results showed that cutting speed, feed rate and depth of cut contributed 94.76 %, 0.048 %, and 0.11 % respectively. The predictive model equations were statistically significant with a p-value of < 0.005. The average induced residual stress on the superficial layer from the experiment and simulation were À 367.7 MPa and À 365.6 MPa respectively. The average residual stresses obtained at depths of 0.2 mm, 0.4 mm, and 0.6 mm were À 260 MPa, À 233 MPa, and À 211 MPa, respectively. The proposed model offers a potential solution to reducing the costs of experimental methods.

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Section: Introductionmentioning

confidence: 99%

Finite element based model for predicting induced residual stresses and cutting forces in AISI 1020 steel alloy

Bosire

Muvengei

Mutua

et al. 2023

Materialwissenschaft Werkst

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“…Numerous developments in numerical methods and simulations associated with the existence of increasingly powerful computers make it possible to study tool wear using FEM. Modeling issues are addressed by considering microstructures as homogeneous characteristics and corresponding verification methods [13][14][15][16][17][18][19][20].…”

Section: Introductionmentioning

confidence: 99%

Study of a Methodology for Calculating Contact Stresses during Blade Processing of Structural Steel

Kozlov,

Babaev,

Schulz

et al. 2023

Metals

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The article presents data about the distribution of contact stresses on the rake surface of the cutter when turning steel (Fe-0.4 C-1Cr), which were obtained by the split cutter method. The article also provides graphs of the effect of the uncut chip thickness a and the rake angle γ on the main parameters of the plots of shear τ and normal σ contact stresses. For this case, The initial data were obtained by longitudinal turning of a steel workpiece with the measurement of the technological components of the cutting force by a three-component Kistler dynamometer, followed by the calculation of the physical components of the cutting force. The rake angle varied widely, from +35 to −10°, and the uncut chip thickness a varied from 0.05 to 0.37 mm. A decrease in the rake angle from +35 to −10° leads to a significant increase in the maximum normal contact stress at the cutting edge σmax: from 400 to 1400 MPa with the uncut chip thickness a = 0.37 mm. In the area of small uncut chip thickness, a (less than 0.1 mm), the paradoxical increase in the magnitude of the greatest normal contact stress with a large positive rake angle (more than +15°) is explained by the indentation (pressing) of the being machined material under the rounded cutting edge of the cutter in the chip formation zone, and their paradoxical decrease with a negative rake angle is due to the presence of a sag (deflection) of the transient surface. According to the magnitude of the reference points obtained on the basis of experimental data, it is possible to plot the contact stresses epures on the rake surface of the cutting tools when machining steel.

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“…Nowadays, the analyses of heat distribution in the cutting zone are often supported by the results of computer simulations or thermographic measurements. The finite element method (FEM) [6] and [7], as well as the boundary element method (BEM) [8] and [9], are usually used for computer simulations, less often the finite difference method (FDM) [1] and [10] is utilised. The wide popularity of these calculation methods is due to their universality.…”

Section: Introductionmentioning

confidence: 99%

Temperature and Heat Partition Testing in the Cutting Zone for Turning AISI 321 Steel

Bartoszuk

2020

SV-JME

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This article shows selected results of experimental tests and the results of analytical and numerical modelling of the thermal characteristics of the cutting process. The tests were conducted for the case of the dry turning of austenitic steel AISI 321 with cutting tools with a flat rake face. The research aimed to determine the actual division of thermal fluxes in the zone of contact between the chip and the rake face. As a result of such work, a formula for a new heat partition coefficient and a formula for calculating the average contact temperature were developed. The results showed that the formulas developed can be a useful tool to estimate heat distribution in the cutting zone quickly.

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Finite element simulation and experimental validation of the effect of tool wear on cutting forces in turning operation

Cited by 10 publications

References 21 publications

Finite element based model for predicting induced residual stresses and cutting forces in AISI 1020 steel alloy

Finite element based model for predicting induced residual stresses and cutting forces in AISI 1020 steel alloy

Study of a Methodology for Calculating Contact Stresses during Blade Processing of Structural Steel

Temperature and Heat Partition Testing in the Cutting Zone for Turning AISI 321 Steel

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