Investigation of Effects of Tool Geometry Parameters on Cutting Forces, Temperature and Tool Wear in Turning Using Finite Element Method and Taguchi’s Technique

Giang, Le Hieu; Dai, Mai Duc; Duc, Pham Minh

doi:10.11648/j.ijmea.20160403.12

Cited by 3 publications

(1 citation statement)

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“…The effects of the rake angles observed can be explained by the decrease in temperature and forces due to the reduction in the contact area between the tool-chip interfaces (See Figure 13). It is known that a high negative rake angle leads to high tool-chip contact pressure, generating a high frictional heat and cutting temperature [34,35] resulting in high residual stresses. This is confirmed by [36] and [37], where residual stresses are augmented by reducing the rake angle from a positive to a negative direction.…”

Section: Effect Of the Edge Radius On Residual Stressesmentioning

confidence: 99%

The Influence of Tool Geometry Parameters on Thermo-Mechanical Loads and Residual Stresses Induced by Orthogonal Cutting of AA6061-T6: A Numerical Investigation

et al. 2023

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The residual stresses state that a mechanical part obtained after machining is a crucial factor that impacts its in-service performance. This stress state is influenced by the thermomechanical loads exerted on the parts during the machining process, which are, in turn, determined by the tool parameters, process, and machining conditions. The aim of the present research was to anticipate how the cutting tool’s edge radius, rake angle, and clearance angle would affect the forces, temperature, and residual stresses induced while orthogonally cutting aluminum AA6061-T6. To achieve this, two-dimensional DEFORM™ software was utilized to develop a finite element model. The residual stresses trend results obtained demonstrated that rake angles of 0° and 17.5–20° values with a small edge radius (5 to 10 µm) and clearance angles of 7 and 17.5° values gave higher compressive stresses. The obtained simulated results were in good agreement with the experiments. The cutting forces, the temperature, and the maximum and minimum machining-induced residual stresses were found to be influenced more by the tool edge radius and the tool rake angle. The influence of the clearance angles on the above-mentioned machining responses was the least. Residual stresses can have a significant impact on the in-service performance of machined parts. The obtained results will help engineers select or design tools that promote a desired surface integrity during machining. This task is not obvious in practice because of difficulties in measuring residual stresses and also because the machining parameters and the tool geometry parameters have different and opposite impacts on thermo-mechanical loads, productivity, and on machining induced residual stresses.

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