Analyzing the effect of cutting parameters and tool nose radius on forces, machining power and tool life in face milling of ductile iron and validation using finite element analysis

Abstract

In the present study, the effect of cutting speed, feed rate, and tool nose radius on the forces, cutting power and tool life has been investigated in machining ductile iron. Face milling inserts with 0.8 mm and 2 mm corner radii were tested at three different cutting speeds and feed rates. The experiments were conducted using a full factorial design method and the Analysis of Variance (ANOVA) technique was used to determine the significance of each variable that is responsible for the variation in forces and machining power. AdvantEdge finite element analysis software was used to study the stress zones and temperature distribution on the cutting edge. The study shows that when the feed rate is increased, there is a linear increase in the radial (Fx) and cutting (Fy) forces. The contribution of feed rate on Fx and Fy forces was around 80% and 87%, respectively. However, with a significance of around 17%, the effect of the tool nose radius was pronounced more in the axial direction (Fz force). The finite element analysis showed higher temperature and stress regions in the nose radius zone of the tool with 2 mm corner radius. The lesser contact area between the tool and workpiece of the insert with 0.8 mm nose radius resulted in lower axial force, lower friction, and increased tool life by around 57%.

Machinability analysis in high speed turning of Ti–6Al–4V alloy and investigation of wear mechanism in AlTiN PVD coated tungsten carbide tool

“…Generally, the surface roughness of a machining operation can be controlled by optimizing the cutting parameters [23] or by changing the geometrical features of the tool like corner radius and wiper facet [24]. However, the work-material-dependent properties like composition, mechanical, and metallurgical properties also play a role in determining the surface roughness.…”

Experimental Investigation on the Effect of Different Micro-Geometries on Cutting Edge and Wiper Edge on Surface Roughness and Forces in Face Milling

“…A similar trend was seen for the Fz forces as well. It can also be seen that increasing the cutting speed decreases all the three force components linearly, which is due to the thermal softening of work material at higher cutting speeds that make the tool easier to penetrate and shear [21]. Researchers have reported that cutting speed has the highest impact on the tool-chip interface temperature when compared to feed rate, which results in the softening of work material at the cutting zone.…”

“…The ANOVA table (Table 7) also confirms that the micro-geometry on the cutting and wiper edge has the highest significance of around 76% and 80.9% in determining the Ra and Rz values respectively followed by cutting speed with a significance of 6.65% and 5.95% respectively. Theoretically, the feed rate has a higher impact on the surface roughness rather than the cutting speed [21]. However, surprisingly, feed is seen as the third significant factor, which could be due to the presence of the wiper edge on all the four From the main effect and interaction plots (Figures 5 and 6), it can be interpreted that Insert B gives the superior surface finish values, whereas Insert A produces the least quality surface, which is in line with the trend seen in the Figures 3 and 4.…”

Optimizing turning parameters for improved surface quality and productivity of Al-MMC under dry, wet, and MQL conditions

“…Abrasive wear, notching wear, and diffusion wear is predominantly found. Padmakumar et al [11] studied the effects of cutting on cutting forces, cutting power, and tool life while machining ductile iron. The tool nose radius is highly dominated for developing the cutting forces.…”