Simulation of Turning Process of AISI 1045 and Carbide Tool Using Finite Element Method

In recent years, the applications of finite element method (FEM) in metal cutting operations have proved to be effective in studying the cutting process and chip formation. The simulation results is useful for both researchers and machine tool makers in optimising the cutting parameters and designing new tools. This paper present the application of Finite element method (FEM) in simulating the effect of cutting tool geometries and cutting speed on the effective stress and temperature changes in turning AISI 1045. The tool geometries studied were various rake (alpha) and clearance (beta) in the range of -5 degrees to 5 degrees, and 5 degrees to 9 degrees for alpha and beta respectively, for cutting speed in the range of 100-300 m/min, at constant feed rate of 0.35 mm/rev and depth of cut of 0.18 mm. The effect of cutting speed on turning process was studied for cutting speed in the range of 100-450 m/min, while the feed rate and depth of cut were kept constant at 0.35 mm/rev and 0.3 mm respectively. The simulation simulation results show that the effective stress and cutting temperature on the cutting edge were between 1710Pa to 2040MPa and 880 degrees C to 2080 degrees C respectively while varying the tool geometries. The simulation results also show that by increasing the cutting speed causes a decrease in effective-stress and increase the temperature of the chip formed to certain extend.