The effect of uncoated carbide tool geometries in turning AISI 1045 using finite element analysis

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Abstract

This paper presents the application of Finite element method (FEM) in simulating the effect of cutting tool geometries on the effective stress and temperature increased in turning AISI 1045. In this study, the DEFORM FEM software was used for simulating the orthogonal cutting. The tool geometries studied were various rake (α) and clearance (β) in the range of -5° to 5°, and 5° to 9° for α and β respectively. The effect of various machining parameters of cutting speed (100m/min to 300m/min) and feed rate (0.15mm/rev to 0.35mm/rev) were also investigated. Nose radius (Rn) and depth of cut were kept constant at 0.4mm and 0.18mm respectively. Simulation results for negative rake angle shows minimum temperature of 605°C was obtained using rake angle of -5° and clearance angle of 5° with cutting speed of 100m/min and feed rate of 0.15mm/rev. On the other hand, the minimum effective stress on the cutting edge of 1740MPa was obtained with a rake angle of 5° and clearance angle of 9°. The machining parameters used were cutting speed of 300m/min and feed rate of 0.35mm/rev. Generally, for all the simulation range specified above, the simulation results show that the effective stress and cutting temperature on the cutting edge were between 1700MPa to 1910MPa and 605°C and 2080°C respectively.

Original languageEnglish
Pages (from-to)271-277
Number of pages7
JournalEuropean Journal of Scientific Research
Volume28
Issue number2
Publication statusPublished - 2009

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carbides
Carbide tools
Finite Element Analysis
finite element analysis
Finite Element
rakes
Finite element method
Angle
geometry
Clearance
Temperature
Geometry
Machining
effective stress
Nose
Finite Element Method
Software
Simulation
finite element method
Range of data

Keywords

  • AISI 1045
  • Clearance angle
  • Finite element method
  • Rake angle
  • Uncoated carbide tools

ASJC Scopus subject areas

  • General

Cite this

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title = "The effect of uncoated carbide tool geometries in turning AISI 1045 using finite element analysis",
abstract = "This paper presents the application of Finite element method (FEM) in simulating the effect of cutting tool geometries on the effective stress and temperature increased in turning AISI 1045. In this study, the DEFORM FEM software was used for simulating the orthogonal cutting. The tool geometries studied were various rake (α) and clearance (β) in the range of -5° to 5°, and 5° to 9° for α and β respectively. The effect of various machining parameters of cutting speed (100m/min to 300m/min) and feed rate (0.15mm/rev to 0.35mm/rev) were also investigated. Nose radius (Rn) and depth of cut were kept constant at 0.4mm and 0.18mm respectively. Simulation results for negative rake angle shows minimum temperature of 605°C was obtained using rake angle of -5° and clearance angle of 5° with cutting speed of 100m/min and feed rate of 0.15mm/rev. On the other hand, the minimum effective stress on the cutting edge of 1740MPa was obtained with a rake angle of 5° and clearance angle of 9°. The machining parameters used were cutting speed of 300m/min and feed rate of 0.35mm/rev. Generally, for all the simulation range specified above, the simulation results show that the effective stress and cutting temperature on the cutting edge were between 1700MPa to 1910MPa and 605°C and 2080°C respectively.",
keywords = "AISI 1045, Clearance angle, Finite element method, Rake angle, Uncoated carbide tools",
author = "{A Ghani}, Jaharah and Wahid, {S. W.} and {Che Haron}, {Che Hassan} and Nuawi, {Mohd. Zaki} and {Ab Rahman}, {Mohd Nizam}",
year = "2009",
language = "English",
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TY - JOUR

T1 - The effect of uncoated carbide tool geometries in turning AISI 1045 using finite element analysis

AU - A Ghani, Jaharah

AU - Wahid, S. W.

AU - Che Haron, Che Hassan

AU - Nuawi, Mohd. Zaki

AU - Ab Rahman, Mohd Nizam

PY - 2009

Y1 - 2009

N2 - This paper presents the application of Finite element method (FEM) in simulating the effect of cutting tool geometries on the effective stress and temperature increased in turning AISI 1045. In this study, the DEFORM FEM software was used for simulating the orthogonal cutting. The tool geometries studied were various rake (α) and clearance (β) in the range of -5° to 5°, and 5° to 9° for α and β respectively. The effect of various machining parameters of cutting speed (100m/min to 300m/min) and feed rate (0.15mm/rev to 0.35mm/rev) were also investigated. Nose radius (Rn) and depth of cut were kept constant at 0.4mm and 0.18mm respectively. Simulation results for negative rake angle shows minimum temperature of 605°C was obtained using rake angle of -5° and clearance angle of 5° with cutting speed of 100m/min and feed rate of 0.15mm/rev. On the other hand, the minimum effective stress on the cutting edge of 1740MPa was obtained with a rake angle of 5° and clearance angle of 9°. The machining parameters used were cutting speed of 300m/min and feed rate of 0.35mm/rev. Generally, for all the simulation range specified above, the simulation results show that the effective stress and cutting temperature on the cutting edge were between 1700MPa to 1910MPa and 605°C and 2080°C respectively.

AB - This paper presents the application of Finite element method (FEM) in simulating the effect of cutting tool geometries on the effective stress and temperature increased in turning AISI 1045. In this study, the DEFORM FEM software was used for simulating the orthogonal cutting. The tool geometries studied were various rake (α) and clearance (β) in the range of -5° to 5°, and 5° to 9° for α and β respectively. The effect of various machining parameters of cutting speed (100m/min to 300m/min) and feed rate (0.15mm/rev to 0.35mm/rev) were also investigated. Nose radius (Rn) and depth of cut were kept constant at 0.4mm and 0.18mm respectively. Simulation results for negative rake angle shows minimum temperature of 605°C was obtained using rake angle of -5° and clearance angle of 5° with cutting speed of 100m/min and feed rate of 0.15mm/rev. On the other hand, the minimum effective stress on the cutting edge of 1740MPa was obtained with a rake angle of 5° and clearance angle of 9°. The machining parameters used were cutting speed of 300m/min and feed rate of 0.35mm/rev. Generally, for all the simulation range specified above, the simulation results show that the effective stress and cutting temperature on the cutting edge were between 1700MPa to 1910MPa and 605°C and 2080°C respectively.

KW - AISI 1045

KW - Clearance angle

KW - Finite element method

KW - Rake angle

KW - Uncoated carbide tools

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