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Materials Today: Proceedings 5 (2018) 8364–8373 www.materialstoday.com/proceedings
IMME17
Abstract
During machining operation, friction between work piece-cutting tool and cutting tool-chip interfaces results high
temperature on the cutting tool. The effect of thus generated heat leads to shorter tool life, higher surface roughness and lowers
the dimensional sensitiveness of work material. This effect is more predominant when machining of difficult-to-cut materials,
due to occurrence of higher heat. In this study aims to simulate a three-dimensional oblique cutting operations using FEM
software (Deform-3D) to study the effects of cutting speed, feed, depth of cut on cutting forces and temperature. The experiments
are performed on a precision lathe and AL 7075-T6 material as a work piece and coated titanium carbide (TiC/Al2O3/TiN) as a
cutting tool materials. The forces have been measured by 4-component KISTLER Dynamometer and temperatures have been
measured by KIMO Infrared sensor thermometer (Spectral response: 8 - 14 µm). The experimental results are compared with the
outputs of finite element temperature model, considering the maximum temperatures at the tool–work piece interface.
1. Introduction
Machining is an essential process of finishing by which jobs are produced to the desired dimensions and
surface finish by gradually removing the excess material from the preformed blank in the form of chips with the
help of cutting tool(s) moved past the work surface(s). The experimental approach to study machining process is
expensive and time consuming especially when a wide range of parameters included like tool geometry, materials,
cutting conditions and so on. Because of these difficulties alternative approaches developed as mathematical
simulations where numerical methods are used. Among these numerical methods, finite element method is proved
to be useful and widely used.
1.1. Orthogonal cutting & oblique cutting
Two types of cutting are used in analysis of metal cutting mechanics:
Orthogonal cutting
Oblique cutting.
In orthogonal cutting, unwanted material is removed from the work piece by a cutting edge that is
perpendicular to the direction of relative motion between tool and the work piece as shown in Fig. 1(a). In
orthogonal cutting, the material removal process is assumed to be uniform along the cutting edge; therefore it is a
two dimensional plane strain problem.
In oblique cutting, the major cutting edge is inclined to direction of the cutting velocity with an inclination
angle as shown in Fig. 1(b).
Although most of the metal cutting operations are oblique, orthogonal cutting has been extensively studied
because of its simplicity and giving good approximations [1].
temperatures has been developed for turning of EN-31 steel alloy with tungsten carbide tools by response surface
methodology coupled with factorial design. The first order and second-order mathematical models are found to be
adequately representing the cutting temperatures [3].
The polycrystalline tool has superior performance in terms of cutting and feed forces and temperatures when
compared to the cemented carbide tool. On average, the cutting and feed forces are lower in the PCD tool for all
cutting speeds when compared to the K10 tool. This has advantages for the machining process because it increases
the tool life. The same is true for the temperature. In the PCD tool, the temperature is always lower for all the
simulated cutting speeds. This also increases the tool life. The temperature measurement methods and the analytical
and numerical models for the prediction of temperature and temperature distribution in metal cutting. FE modeling
and simulation of machining processes is mainly suffering from a lack of the fundamental input data. Therefore,
further effort is required to provide a clear, consistent, well measured and relevant data on material behavior under
conditions of interest [4].The validation of a previously developed finite difference time domain temperature
prediction model is carried out for orthogonal machining process with an IR camera set-up, considering the
temperature distribution in the tool [5].
The objective of this work has been to create reliable FEM models to simulate three-dimensional cutting
operations that can be used in the future for further investigations. That is why we set up two reference models for
three-dimensional cutting operations and proved their reliability by comparing the simulated and experimental
results in terms of chip geometry and cutting load. The final result can be considered to be very good [6].The
temperature generated on the cutting tool and experimental methods for the measurement of temperatures are
reviewed. Special attention has been paid to tool- work thermocouple method and an experimental setup fabricated
to measure the temperature on the cutting tool and work piece junction during metal cutting is described [7].
3. Experimentation
The design of experiments has a major effect on the number of experiments needed. Therefore it is essential to
have a proper design of experiments. A L9 33 array was selected in this work so that all the interactions between the
independent variables can be investigated. In this study the three parameters namely cutting speed, feed, depth of cut
of the cutting tool was selected for the experimentation. The range of each parameter was set at three different
levels. Based on L9 33 array, a total of 9 experiments for coated cutting tool(TiC/Al2O3/TiN), each having a
combination of different levels of factors as shown in Table 1 were carried out. The experiments were replicated
thrice to overcome effect on response due to random variation and average values were noted down.
The multi component dynamometer provides dynamic and quasi-static measurement of the 3-orthogonal
components of force (Fx, Fy, Fz) acting from any direction onto the top plate as well as the moments Mz.
Researchers usually wrote their own FE codes for specific process such as metal cutting analysis until the mid-
1990s. In recent years, commercial FE packages such as DEFORM 2D/3D, ABAQUS, ADVANTEDGE, LS-DYNA
etc., It has been used excessively in both academic and industrial world for process analysis [8].
Fig.6: Meshed Tool and Work piece Fig. 7: Mesh design of a work piece
5.3.1. Variation of Cutting force with cutting speed at different feeds of TiC/Al203/TiN Cutting tool
Fig. 9,10,11, and 12 shows how the cutting forces evolve with the variation of cutting speed for both TiC
/Al203 / TiN and K10 tools (the simulation was performed in DEFORM 3D).The cutting forces are substantially
lower in TiC / Al203 / TiN .In order to validate the finite element model, the predicted and experimentally measured
cutting forces and highest temperature of the tool- work piece interface were compared. The values obtained by the
finite element model are shown in Fig. 13 and Fig 14. Below figures shows that the predicted maximum cutting
forces in Y direction are 211.81 & 167.86.by FEM and 230.26 N & 181.58N by experiments using coated and
uncoated tools respectively.
Fig 9: Experimental model of TiC/Al203/TiN tool Fig 10: FE model of TiC/Al203/TiN tool
8372 Sreeramulu et al., / Materials Today: Proceedings 5 (2018) 8364–8373
5.3.2. Variation of Cutting force with cutting speed at different depth of cuts of TiC/Al203/TiN Cutting tool
Fig 11: Experimental model of TiC/Al203/TiN tool Fig 12: FE model of TiC/Al203/TiN tool
Fig 13: FEM model using TiC/Al2O3/TiN tool Fig 14: Experimental model using TiC/Al2O3/TiN
Fig. 15 shows how the temperature evolves for both tools (TiC/ Al2O3 /TiN ) with a variation of the cutting
speed. It can be seen that the TiC/Al203/TiN tool has a lower temperature for all cutting speeds. For a cutting speed
of120 m/min, feed of 0.2 mm/rev and depth of cut of 1.5 mm, for example, the temperature in the TiC/ Al2O3 /TiN
reached 96°C [10].
Fig 16: Experimental model TiC/Al203/TiN of tool Fig 17: FE model TiC/Al203/TiN of tool
Sreeramulu et al., / Materials Today: Proceedings 5 (2018) 8364–8373 8373
The Fig. 16, 17, 18 and 19 shows a relation of cutting speed versus temperature at different feeds used in
experimentation work. The inference that can be drawn from the above graph is that when we increase the cutting
speed the temperatures keep on decreasing [11&12].
5.3.4. Variation of Temperature with cutting speed at different depth of cuts of TiC/Al203/TiN Cutting tool
Fig 18: Experimental model TiC/Al203/TiN of tool Fig 19: FE model TiC/Al203/TiN of tool
6. Conclusion
The results obtained in predicting the outputs of cutting operation using well known FEM three dimensional
models have shown and those results are compared with experimental data. One of the advantages of using
numerical simulation instead of experimentation is the ability to predict thermal and mechanical behavior of both the
material and the tool without spending time and money with experimental procedures. Thereby, improving
productivity and reducing costs. However, accuracy of the results obtained with finite element methods depends
mainly on the accuracy of the input values. Thus, understanding how the input data affect the prediction of the FEM
analysis is fundamental, leading the way to more reliable simulation of the machining processes.
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