A Numerical Model for Predicting the Effect of Tool Nose Radius on Machining Process Performance during Orthogonal Cutting of AISI 1045 Steel

Abstract

This paper presents the development of a numerical model for predicting and studying the effects of tool nose geometries and its interactions with cutting parameters during orthogonal cutting of AISI 1045 steel. The process performance characteristics studied were cutting temperature, effective stress, cutting forces and tool wear. The cutting simulations were done using the commercial DEFORM-2D R V 11.3 software, based on the finite element method (FEM). The cutting tool used had a round nose with various nose radii (0.01–0.9 mm), while the machining parameters tested were the feed rate (0.1–0.3 mm/rev), the cutting speed (100-500 m/min) and the rake angle (–5° to +10°). The interactions between the tool nose radius and the cutting parameters (speed, feed) were found to affect mostly the cutting stress and, slightly, the tool wear rate. These interactions did not much influence the cutting temperature, that was found to be high when the tool nose radius and/or the cutting speed were high. The maximum temperature was found to occur at the middle of the tool-chip contact length and at the interaction of nose radius and flank face of the tool. Except for some fluctuations, there was no significant difference in tool wear rate between small and large nose radius scales.

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

“…They saw that increasing the edge radius from 0.01 to 0.1 mm caused an increase in the cutting forces and temperature. Javidikia et al [5] and Tagiuri et al [21] made similar conclusions.…”

“…However, the influence of the rake angle on the residual stresses distribution was not studied. Özel et Orthogonal cutting is widely used for simulating the machining processes [1,10,11,[19][20][21]. The use of Finite Element methods (FEM) helps assessing responses that are difficult to measure and reduces expensive experimental tests.…”

“…However, the effect of tool geometry on residual stresses was not discussed. Tagiuri et al [21] developed an FE model to predict the effect of the tool nose radius (10 to 900 µm), rake angle (−5 • to +10 • ), feed rate, and cutting speed on the cutting temperature, effective stresses, cutting forces, and tool wear during dry turning of AISI 1045 steel. Their results showed that for a certain nose range, a linear proportionality was proved between the cutting temperature and stresses.…”

Multi objective optimization of process parameters in hard turning of AISI 52100 steel with surface irregularities using GRA-PCA

“…With an increase in nose radius, WST increases gradually. WST rises as the nose radius grows because there is more surface area of the tool in contact with the workpiece and more variation in the cutting stress [47,48]. WST increases with an increase in negative rake angle.…”

“…WST increases with an increase in negative rake angle. Because the contact force between the chip and the cutting tool has increased [48]. WST rises as machining parameters are increased [49,50].…”