Application of FEM in Investigating Machining Performance

Abstract

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.

CAD-Based 3D-FE Modelling of AISI-D3 Turning with Ceramic Tooling

“…Xiong et al [4] studied the chip formation process during the orthogonal cutting of TiB 2 /7050Al composite, along with the strain rate and the developed temperatures with the aid of 2D-FEM. More similar researches prove that the use of FEM can become a valuable asset when investigating typical machining results such as the tool/chip contact temperatures [5], the chip formation mechanisms [6,7], and the generated cutting forces, as well as the tool wear mechanisms [8][9][10][11].…”

Digital Modeling of End-Mill Cutting Tools for FEM Applications from the Active Cutting Contour

“…This simulation method has appeared undoubtedly effective in the analysis of several studies in the machining processes by chip removal, as the temperature, stress and plastic strain distributions, chip and burr generation, cutting efforts, etc. Also, with these simulations is possible to obtain a first approximation of the behavior in service of the cutting tools, without need to realize long and costly machining tests [6].…”