Abstract. Demand for higher productivity and good quality for machining parts has encourage many researchers to study the effects of machining parameters using FEM simulation using either two or three dimensions version. These are due to advantages such as software package and computational times are required. Experimental work is very costly, time consuming and labor intensive. The present work aims to simulate a three-dimensional orthogonal cutting operations using FEM software (deform-3D) to study the effects of rake angle on the cutting force, effective stress, strain and temperature on the edge of carbide cutting tool. There were seven runs of simulations. All simulations were performed for various rake angles of -15 deg, -10 deg, -5 deg, 0 deg, +5 deg, +10 deg, and +15 deg. The cutting speed, feed rate and depth of cut (DOC) were kept constant at 100 m/min, 0.35 mm/rev and 0.3 mm respectively. The work piece used was ductile cast iron FCD500 grade and the cutting tool was DNMA432 series (tungsten, uncoated carbide tool, SCEA = 0; and radius angle 55 deg). The analysis of results show that, the increase in the rake angle from negative to positive angle, causing the decrease in cutting force, effective stress and total Von Misses strain. The minimum of the cutting force, effective stress and total Von Misses strain were obtained at rake angle of +15 deg. Increasing the rake caused higher temperature generated on the edge of carbide cutting tool and resulted in bigger contact area between the clearance face and the workpiece, consequently caused more friction and wear. The biggest deformation was occurred in the primary deformation zone, followed by the secondary deformation zone. The highest stress was also occurred in the primary deformation zone. But the highest temperature on the chip usually occurs in secondary deformation zone, especially in the sliding region, because the heat that was generated in the sticking region increased as the workpiece was adhered by the tool and later it was sheared in high frictional force.
This paper presents investigations on the performance of uncoated and multi-layer coated carbide tools while turning ductile cast iron FCD700. Three different squares-edged carbide tools were used, namely TiN+TiCN+Al 2 O 3 +TiN-coated carbide tools, multi-layered hard coating of 5 and 10 µm thickness and an uncoated WC/Co tool. Deform-3D FEM software is utilised to predict the main cutting force, the sliding velocity, interface temperature and interface pressure and tool wear rate on these inserts. The results show that the main cutting forces obtained with multi-layer carbide tools are smaller than the uncoated carbide tool. The simulated results for cutting forces were validated experimentally, and the maximum error between the simulation and experimental results is 8.14 %. It was found that the coated carbide tool with the highest thickness is the most suitable for turning ductile cast iron at higher cutting speeds.
Abstract.The two biggest problems that often experienced in machining cast iron are poor machinability and high hardness. Up to now, many researchers have investigated machining performance and how to find optimum condition in machining ductile cast iron. This study aims to investigate the machining performance of ductile cast iron and carbide cutting tool using FEM. Performances were evaluated by changing the cutting tool geometries on the machining responses of cutting force, stress, strain, and generated temperature on the workpiece. Deform-3D commercial finite element software was used in this study. Ductile cast iron FCD 500 grade was used as the work piece material and carbide insert DNMA432 type with WC (Tungsten) was used for the cutting tool. The effects of rake and clearance angles were investigated by designing various tool geometries. Various combination of carbide insert geometries were designed using Solid Work to produce +15, +20 and +30 deg for rake angle and 5, 7, 8 and 9 deg for clearance angle. Machining condition for the simulations were remained constant at cutting speed of 200 m/min, feed rate of 0.35 mm/rev, and depth of cut of 0.3 mm. The results of effective-stress, strain and generated temperature on both chip and material surface were analysed. The results show that by increasing the rake angle (α), it will improves the machining performance by reducing the cutting force, stress, strain and generated temperature on surface of workpiece. But, by increasing the clearance angle (γ), it will not affect much to the cutting force, stress, strain and generated temperature on chip.
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