Print ISSN: 1681-6900

Online ISSN: 2412-0758

Keywords : Finite element simulation

Experimental and FEM Study of Coated Inserts on Cutting Forces in Orthogonal Cutting

Maan A. Tawfiq; Basim S. Sahib

Engineering and Technology Journal, 2015, Volume 33, Issue 3, Pages 694-702

In this study, an attempt has been made to investigate and simulate the influence of coated layers, on the cutting force components in orthogonal turning process using AISI 1010 steel.A series of experimental and numerical tests have been done with four types of inserts including uncoated, coated tool with (TiN), (TiN /TiCN) and (TiN /Al2O3/ TiCN) using the special FEA code (DEFORM-2D). The turning tests were conducted at five different cutting speeds (45, 65, 97, 145, and 206 m/min.), while feed rate and depth of cut were kept constant at (0.2 mm/rev.) and (1.2 mm) respectively.
The results show that the minimum force is achieved when using TiN/TiCN insert compared with other inserts in all cutting conditions. The cutting force components (tangential and feed force) are decreasedby (22% and 69% respectively) when the cutting speedincreases from (45 to 206) m/min. The maximum relative difference between simulated and measured values is less than (17%).

Finite Element Analysis to Study The Effects Of The Workpiece flowStress Models on Cutting Variables in Orthogonal Cutting

Raheem Sadoon Jamel

Engineering and Technology Journal, 2012, Volume 30, Issue 14, Pages 2507-2521

Turning process is a common machining process to produce cylindrical shape parts. Understanding of material removal concepts in metal cutting is very important in design process and cutting tool selection to ensure the quality of the products. For this purpose, orthogonal cutting simulations of AISI 1045 steel are performed and the model used in simulations is validated. Effects of work piece flow stress
models on cutting variables such as cutting forces, chip geometry and temperature are investigated by comparing simulation results with experimental results available in the literature. Results show that flow stress models have a major effect on calculated results .The results of the simulations show that Oxley material model is able to give more accurate results for used cutting conditions in the analysis, however errors in calculating shear angle and thrust force are higher than Johnson-cook and Zerilli-
Armstrong material models.