Effect of Tool Geometry in Turning AISI 1045 Steel: Experimental Investigation and FEM Analysis

Tool geometry selection and its optimization are complex tasks involving many considerations, since the geometries chosen will have individual influence and combined influence along with the other values on the machining process. In this investigation, geometrical parameters of cutting tool insert such as insert shape (including angle of cutting edge), relief angle and nose radius are chosen for analysis maintaining the machining parameters constant. Experiments are designed using Taguchi’s design of experiment and the output quality characteristics such as flank wear, surface roughness and material removal rate (MRR) are analyzed using signal-to-noise ratio and analysis of variance. For three parameters, varied through three levels, a suitable L9 orthogonal array is chosen. Nine different ISO-designated cutting tool inserts of various shapes, relief angle and nose radius are used in this analysis. From the experimental results, it is found that cutting insert shape is the most significant factor contributing by 45.27 % followed by nose radius by 36.37 % and relief angle by 5.28 % toward the response. A confirmation experiment and finite element analysis are performed for the optimal geometrical parameters. From the investigation, considerable improvement in the performance of cutting tool insert is observed.