Modeling and simulation of temperature generated on work piece and chip formation in orthogonal machining

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2 Citations (Scopus)

Abstract

Experimental investigation in machining operation for the temperature generated on work piece, chip formation and cutting tool are difficult, time consuming and costly to carry out. FEM's machining simulation Using Deform-3D is an alternative. This paper presents a simulation study of temperature generated on work piece and chip formation for various tool geometries combinations (rake angle and clearance angle). Ductile cast iron FCD500 grade was used as material work piece, and uncoated DNMA432 carbide tools were used as cutting tool. Twelve designs of carbide tools with various combinations of rake angle (15, 20, and 30 deg) and clearance angle (5, 7, 8 and 9 deg) were designed. The nose radius of the cutting tool was kept constant at 0.4 mm. Machining parameters of cutting speed, feed rate and dept of cut (DOC) were kept constant at 200 m/min, 0.35 mm/rev and 3 mm respectively. After machining simulations were carried out, temperature generated on work piece and chip formation was analyzed. The results show that by increasing the rake angle, the machining performance is improved due to the low temperature generated on the machined surface, as well as low cutting force, stress, and strain. On the other hand, increasing/decreasing the clearance angle, does not significantly affected the cutting force, stress, and strain, consequently it does not affected the temperature generated. The highest temperature occurred in the sliding region due to the work piece material adheres to the cutting tool and shear occurs within the chip, the frictional force is very high; consequently heat is generated from this sticking region.

Original languageEnglish
Pages (from-to)340-348
Number of pages9
JournalInternational Review of Mechanical Engineering
Volume5
Issue number2
Publication statusPublished - Feb 2011

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Machining
Cutting tools
Carbide tools
Temperature
Cast iron
Finite element method
Geometry

Keywords

  • Carbide tool
  • Chip formation
  • Cutting force
  • Generated temperature
  • Tool geometry

ASJC Scopus subject areas

  • Mechanical Engineering

Cite this

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title = "Modeling and simulation of temperature generated on work piece and chip formation in orthogonal machining",
abstract = "Experimental investigation in machining operation for the temperature generated on work piece, chip formation and cutting tool are difficult, time consuming and costly to carry out. FEM's machining simulation Using Deform-3D is an alternative. This paper presents a simulation study of temperature generated on work piece and chip formation for various tool geometries combinations (rake angle and clearance angle). Ductile cast iron FCD500 grade was used as material work piece, and uncoated DNMA432 carbide tools were used as cutting tool. Twelve designs of carbide tools with various combinations of rake angle (15, 20, and 30 deg) and clearance angle (5, 7, 8 and 9 deg) were designed. The nose radius of the cutting tool was kept constant at 0.4 mm. Machining parameters of cutting speed, feed rate and dept of cut (DOC) were kept constant at 200 m/min, 0.35 mm/rev and 3 mm respectively. After machining simulations were carried out, temperature generated on work piece and chip formation was analyzed. The results show that by increasing the rake angle, the machining performance is improved due to the low temperature generated on the machined surface, as well as low cutting force, stress, and strain. On the other hand, increasing/decreasing the clearance angle, does not significantly affected the cutting force, stress, and strain, consequently it does not affected the temperature generated. The highest temperature occurred in the sliding region due to the work piece material adheres to the cutting tool and shear occurs within the chip, the frictional force is very high; consequently heat is generated from this sticking region.",
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N2 - Experimental investigation in machining operation for the temperature generated on work piece, chip formation and cutting tool are difficult, time consuming and costly to carry out. FEM's machining simulation Using Deform-3D is an alternative. This paper presents a simulation study of temperature generated on work piece and chip formation for various tool geometries combinations (rake angle and clearance angle). Ductile cast iron FCD500 grade was used as material work piece, and uncoated DNMA432 carbide tools were used as cutting tool. Twelve designs of carbide tools with various combinations of rake angle (15, 20, and 30 deg) and clearance angle (5, 7, 8 and 9 deg) were designed. The nose radius of the cutting tool was kept constant at 0.4 mm. Machining parameters of cutting speed, feed rate and dept of cut (DOC) were kept constant at 200 m/min, 0.35 mm/rev and 3 mm respectively. After machining simulations were carried out, temperature generated on work piece and chip formation was analyzed. The results show that by increasing the rake angle, the machining performance is improved due to the low temperature generated on the machined surface, as well as low cutting force, stress, and strain. On the other hand, increasing/decreasing the clearance angle, does not significantly affected the cutting force, stress, and strain, consequently it does not affected the temperature generated. The highest temperature occurred in the sliding region due to the work piece material adheres to the cutting tool and shear occurs within the chip, the frictional force is very high; consequently heat is generated from this sticking region.

AB - Experimental investigation in machining operation for the temperature generated on work piece, chip formation and cutting tool are difficult, time consuming and costly to carry out. FEM's machining simulation Using Deform-3D is an alternative. This paper presents a simulation study of temperature generated on work piece and chip formation for various tool geometries combinations (rake angle and clearance angle). Ductile cast iron FCD500 grade was used as material work piece, and uncoated DNMA432 carbide tools were used as cutting tool. Twelve designs of carbide tools with various combinations of rake angle (15, 20, and 30 deg) and clearance angle (5, 7, 8 and 9 deg) were designed. The nose radius of the cutting tool was kept constant at 0.4 mm. Machining parameters of cutting speed, feed rate and dept of cut (DOC) were kept constant at 200 m/min, 0.35 mm/rev and 3 mm respectively. After machining simulations were carried out, temperature generated on work piece and chip formation was analyzed. The results show that by increasing the rake angle, the machining performance is improved due to the low temperature generated on the machined surface, as well as low cutting force, stress, and strain. On the other hand, increasing/decreasing the clearance angle, does not significantly affected the cutting force, stress, and strain, consequently it does not affected the temperature generated. The highest temperature occurred in the sliding region due to the work piece material adheres to the cutting tool and shear occurs within the chip, the frictional force is very high; consequently heat is generated from this sticking region.

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