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European Journal of Scientific Research

ISSN 1450-216X Vol.28 No.2 (2009), pp.271-277


© EuroJournals Publishing, Inc. 2009
http://www.eurojournals.com/ejsr.htm

The Effect of Uncoated Carbide Tool Geometries in Turning


AISI 1045 Using Finite Element Analysis

Jaharah A.G
Dept. of Mechanical & Material Engineering
Faculty of Engineering and Built Environment
Universiti Kebangsaan Malaysia, 43600 Bangi, Selangor, Malaysia
E-mail: jaharah@eng.ukm.my
Tel: +603 89216505; Fax: +603 89259659

Wahid S.W
Dept. of Mechanical & Material Engineering
Faculty of Engineering and Built Environment
Universiti Kebangsaan Malaysia, 43600 Bangi, Selangor, Malaysia
E-mail: sizawa@eng.ukm.my
Tel: +603 89216505; Fax: +603 89259659

Che Hassan C.H


Dept. of Mechanical & Material Engineering
Faculty of Engineering and Built Environment
Universiti Kebangsaan Malaysia, 43600 Bangi, Selangor, Malaysia
E-mail: chase@eng.ukm.my
Tel: +603 8921516; Fax: +603 89259659

Nuawi M.Z
Dept. of Mechanical & Material Engineering
Faculty of Engineering and Built Environment
Universiti Kebangsaan Malaysia, 43600 Bangi, Selangor, Malaysia
E-mail: zaki@eng.ukm.my
Tel: +603 89216507; Fax: +603 89259659

Mohd Nizam Ab Rahman


Dept. of Mechanical & Material Engineering
Faculty of Engineering and Built Environment
Universiti Kebangsaan Malaysia, 43600 Bangi, Selangor, Malaysia
E-mail: mnizam@eng.ukm.my
Tel: +603 89216449; Fax: +603 89259659

Abstract

This paper presents the application of Finite element method (FEM) in simulating
the effect of cutting tool geometries on the effective stress and temperature increased in
turning AISI 1045. In this study, the DEFORM FEM software was used for simulating the
orthogonal cutting. The tool geometries studied were various rake (α) and clearance (β) in
The Effect of Uncoated Carbide Tool Geometries in Turning AISI 1045 using
Finite Element Analysis 272

the range of -5° to 5°, and 5° to 9° for α and β respectively. The effect of various machining
parameters of cutting speed (100m/min to 300m/min) and feed rate (0.15mm/rev to
0.35mm/rev) were also investigated. Nose radius (Rn) and depth of cut were kept constant
at 0.4mm and 0.18mm respectively. Simulation results for negative rake angle shows
minimum temperature of 605°C was obtained using rake angle of -5° and clearance angle
of 5° with cutting speed of 100m/min and feed rate of 0.15mm/rev. On the other hand, the
minimum effective stress on the cutting edge of 1740MPa was obtained with a rake angle
of 5° and clearance angle of 9°. The machining parameters used were cutting speed of
300m/min and feed rate of 0.35mm/rev. Generally, for all the simulation range specified
above, the simulation results show that the effective stress and cutting temperature on the
cutting edge were between 1700MPa to 1910MPa and 605°C and 2080°C respectively.

Keywords: Uncoated carbide tools, AISI 1045, Finite Element Method, rake angle,
clearance angle.

1. Introduction
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. (Shet & Deng 2000).
Recently, the application of finite element method (FEM) in metal cutting process was a great
help for researchers in study of metal cutting and chip formation. Numerical simulation is used to study
various phenomenon such as, chip segmentation, cutting force and wear rate of cutting tool (Umbrello
et al. 2007). The cutting force is normally influenced by machining parameters; cutting tool
geometries, machining conditions and wear of cutting tool (Zoorev 1966). The wear of the cutting tool
was the critical issue in metal cutting as well as in turning of metal, consequently caused the tool
failure (Woodrow 2005).
Numerical model is found to be a good, suitable and capable to forecast the effect of machining
parameters such as wear of cutting tool, cutting tool failure and the machined surface (Ozel & Zeren
2004). The success and reliability of numerical model are highly depended on the flow stress of work
materials, i.e. tension models, tension rate and temperature, and the friction between the work material
and the cutting edge (Childs 1998). The geometry of the cutting tool is very important in determining
the values of the cutting force (Saglam et al. 2005). Machining parameters must be right and carefully
selected to ensure the longer life of the cutting tool and therefore minimized the machining cost (Yang
& Tarng 1998).
Generally, machinability is defined the as a combination of optimum machining parameters
such as low cutting force, high metal removal rate, good surface integrity, accurate and consistent work
piece geometry characteristics, low wear rate, and acceptable chip formation (Noordin et al. 2003).
According to Lo (2000), rake angle is an important factor influencing the stress on the cutting edge
when compared to other factors such as clearance angle and nose radius. Furthermore, the stress on the
cutting edge decreases with the increases of the rake angle (Lo 2000).
Steel alloy AISI 1045 is used in this study due to its suitability and widely used in the model by
previous researcher (Iqbal et al. 2006). In turning of steel, coated carbide tool perform better than
uncoated carbide tool (Ozel & Zeren 2004).
In this study the performance of the uncoated carbide tools is studied by varying the cutting tool
geometries of the rake and clearance angles in turning AISI 1045. The simulation results of cutting
edge temperature and its effective stress are presented and discussed. The uncoated tool is selected to
eliminate the effect of coating material in the simulation results.
273 Jaharah A.G, Wahid S.W, Che Hassan C.H, Nuawi M.Z and Mohd Nizam Ab Rahman

2. Modelling using the Finite Element Method


DEFORM software is used to simulate the orthogonal cutting process, which is based on the
Lagrangian equation. The software is used to simulate the geometry of the cutting tool and machining
parameters in turning the AISI 1045 using uncoated carbide tool. Simulation process is carried out by
changing the rake, clearance angle, cutting speed and feed rate. Later, the effective stress and
temperature on the cutting edge are analysed.
Initial temperature for the work material and the cutting tool is set at 27°C. Simulation is
carried out to reach at steady state, which allowed the thermal to flow into the work material during the
simulation of the cutting process. Later, the simulation is continued to reach the transient condition.
Tool stress analysis is performed to obtain stress data on the cutting tool. Cutting tool will be fixed as
an elastic and the force is interpolated so that the system will interpolate the force on the cutting tool to
produce the resultant cutting force acting on the cutting edge.
Work material is assumed to be a rigid-viscoplastic in a rectangle shaped. The cutting tool is
classified as rigid body and will consider temperature transfer to model the cutting temperature.
Properties of stress flow, physical, and work material thermal-mechanical are shown in Table 1. Table
2 shows the parameters used in the simulation process

Table 1: Work material properties

− − − '
Work Material; AISI 1045 (Oxley’s Equation - σ = σ (ε , ε , T ) )
i) Flow stress data
Temperature ºC 20 100 300 500 700 900 1200
Strain 0.05 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0
Strain rate 1 10 100 1000 10000 100000 500000
ii)Thermal conductivity 50.8W/mK
-Temperature ºC 20 - 1500
iii) Thermal expansion
-Temperature ºC -100 - 1500
iv) Heat capacity
-Temperature ºC -100 - 1500
v) Young modulus
-Temperature ºC -100 - 1500

Table 2: Input parameters used in the simulation process

Parameters
Rake angle (˚) -5 +0 +5
Clearance Angle (˚) +5 +7 +9
Cutting speed (m/min) 100 200 300
Feed Rate (mm/rev) 0.15 0.25 0.35
Depth of cut (mm) constant at 0.18mm
Nose Radius (Rn) (mm) constant at 0.4 mm
Heat transfer coefficients at the workpiece- tool interface 0.1 N/s mm ˚C

3. Result and Discussion


Finite element analysis is used to study the temperature changes and effective stress with different
combination of rake angle, clearance angle, cutting speed, and feed rate. Table 3 shows the simulation
results obtained using L9 orthogonal array for temperature and stress. The simulation results also show
that the chip thickness obtained is 0.5 mm for all the nine simulations. Huang and Black (1996)
explained that the criteria for chip separation will not greatly influence the stress and tension
distribution.
The Effect of Uncoated Carbide Tool Geometries in Turning AISI 1045 using
Finite Element Analysis 274

Table 3: Simulation results using L9 orthogonal array for the temperature and effective stress on the cutting
edge.

Rake Angle, Clearance Cutting Speed Feed Rate Temperature Effective Stress
No.
α, (º) Angle, β, (º) (mm/min) (mm/rev) (˚C) (MPa)
1. -5 5 100 0.15 605 1850
2. -5 7 200 0.25 1200 2040
3. -5 9 300 0.35 2080 1740
4. 0 5 200 0.35 1420 2040
5. 0 7 300 0.15 1350 1930
6. 0 9 100 0.25 740 1930
7. 5 5 300 0.25 1730 1700
8. 5 7 100 0.35 880 1710
9. 5 9 200 0.15 1110 1910

Generally, it is found that the temperature increases when using negative rake angle. According
to Gunay et al. (2005), negative rake angle will increase the cutting force and therefore high heat will
be generated. The effective stress obtained from the simulation process is between 1700MPa to
2040MPa. The minimum stress is achieved at a combination of +5° of rake and clearance angles. This
result is agreeable with the findings from Lo (2000). According to him, the stress on the cutting edge
will decreases with increases of rake angle. Baradie (1995) found that the optimum clearance angle for
carbide tool is between -11° to +5°. Small changes in clearance angle will greatly influence the wear
mechanism and consequently the tool life (Coelho et al. 2004). Table 4 shows the analysis of variance
for cutting temperature.

Table 4: ANOVA for cutting temperature.

Degree of Sum of Percentage


Parameter Variance (V) F-ratio Total
Freedom (F) Squared (S) (P%)
Rake angle 2 23550 11775 - 23550 1.31
Clearance angle 2 42916.67 21458.33 - 42916.67 2.40
Cutting speed 2 1436017 718008.3 - 1436017 80.17
Feed rate 2 288816.7 144408.3 - 288816.7 16.12
Error 0
Total 8 1791300 100

ANOVA analysis performed in Table 4 shows, that the temperature on the cutting edge is
influenced by the cutting speed of 80.17%, followed by feed rate of 16.12%, clearance angle of 2.4%
and rake angle of 1.31%. Generally, high cutting speed and feed rate will caused high temperature
generated. Whereas at medium combination of cutting speed and feed rate will caused higher effective
stress. These phenomena will promote wear rate as stated by Sanglam et al. (2005), where increased in
positive rake angle at high cutting speed will reduce the cutting force, but according to Gunay et al.
(2005), temperature at the cutting edge increases with increased in contact area between chips and the
cutting edge. According to Coelho et al. (2004), reducing the clearance angle while fixing the rake
angle, will generate wear on the cutting edge, and therefore shorten the tool life. Cutting with high
clearance angle will cause bigger contact area between the cutting edge and the work material,
consequently increases the cutting temperature as discussed by Saglam et al. (2005).
275 Jaharah A.G, Wahid S.W, Che Hassan C.H, Nuawi M.Z and Mohd Nizam Ab Rahman
Table 5: ANOVA for effective stress at the cutting edge

Degree of Sum of Squared Variance


Parameter F-ratio Total Percentage (P%)
Freedom (F) (S) (V)
Rake angle 2 56155.56 28077.78 - 56155.56 40.59
Clearance angle 2 2022.222 1011.111 - 2022.222 1.46
Cutting speed 2 72088.89 36044.44 - 72088.89 52.10
Feed rate 2 8088.889 4044.444 - 8088.889 5.85
Error 0
Total 8 138355.6 100

Table 5 shows the ANOVA performed for effective stress on the cutting edge. The analysis
shows that the effective stress is controlled mainly by the cutting speed with contribution of 52.10% ,
followed by the rake angle of 40.59%, feed rate of 5.85% and clearance angle of 1.46%. Nalbant et al.
(2006) found that, any changes in clearance angle, would cause damage on the cutting edge. Whereas,
Lo (2000) found that, the normal and effective stresses acting on the cutting edge, decrease with
increases in rake angle form negative to positive values. More force is required for negative rake angle
to overcome the existing resistance force. Consequently the stress on the cutting edge increase (Lo
2000).
Figure 1(a-b) show examples of the simulation process using finite element method. In these
examples the rake and clearance angles are 5° and 7° respectively. The cutting speed and feed rate are
at 100m/min and 0.35mm/rev respectively. Figure 1(a) shows that the temperature is at 880°C, while
Figure 1 (b) indicate that the effective stress is at 1710MPa with the same input parameters.

Figure 1: (a-b) Temperature and effective stress at 5° and 7° rake and clearance angles respectively

a) Temperature b) Effective stress

4. Conclusions
The following can be concluded from the simulation results obtained;
1. The minimum temperature of 605°C on the cutting edge is obtained using rake and clearance
angles of -5° and 5° respectively with cutting speed of 100mm/min, and feed rate of
0.15mm/rev.
2. The minimum effective stress of 1700MPa is achieved using rake and clearance angles of 5°
and 5° respectively with cutting speed of 300mm/min, and feed rate of 0.25mm/rev.
3. Analysis of ANOVA for cutting temperature on the cutting edge revealed that the cutting speed
contribute 80.17%, followed by feed rate of 16.12%, clearance angle of 2.4% and rake angle of
1.31%.
The Effect of Uncoated Carbide Tool Geometries in Turning AISI 1045 using
Finite Element Analysis 276

4. Cutting speed is also the main caused to the effective stress generated on the cutting edge with
contribution of 52.10%, followed by rake angle of 40.59%, feed rate of 5.85%, and clearance
angle of 1.46%.

Acknowledgement
The authors would like to thank the Universiti Kebangsaan Malaysia, and Ministry of Science and
Innovation (MOSTI) for supporting the project (03-01-02-SF0214).
277 Jaharah A.G, Wahid S.W, Che Hassan C.H, Nuawi M.Z and Mohd Nizam Ab Rahman

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