3D-FEM Approach of AISI-52100 Hard Turning: Modelling of Cutting Forces and Cutting Condition Optimization

Anastasios Tzotzis,Panagiotis Kyratsis,Nikolaos Tapoglou,Rajesh Kumar Verma

doi:10.3390/machines10020074

Abstract

In the present study, a 3D finite element (FE) model for machining AISI-52100 steel was proposed, with respect to three levels of cutting speed (100 m/min, 150 m/min and 200 m/min), feed (0.08 mm/rev, 0.11 mm/rev and 0.14 mm/rev), depth of cut (0.20 mm, 0.30 mm and 0.40 mm) and tool nose radius (0.80 mm, 1.20 mm and 1.60 mm). Nine simulation tests were performed according to cutting conditions that were used in experimental studies, in order to verify the accuracy of the model. Next, the FE model was utilized to carry out thirty new simulation runs, with cutting conditions derived from the implementation of the central composite design (CCD). Additionally, a mathematical model was established for prediction purposes, whereas the relationship between the applied cutting parameters and their influence on the resultant cutting force was investigated with the aid of statistical methodologies such as the response surface methodology (RSM) and the analysis of variance (ANOVA). The comparison between the numerical and the statistical model revealed an increased level of correlation, superseding 90% in many tests. Specifically, the relative error varied between −7.9% and 11.3%. Lastly, an optimization process was performed to find the optimal cutting conditions for minimizing the resultant machining force, as per the standardized tool nose radius value.

Highlights

Nine simulation runs were carried out in order to determine the accuracy of the developed finite element (FE) model
The present study indicates that the residuals are almost evenly distributed on both sides of the reference line
With the use of the mathematical model, future experimental testing can be skipped and instant results can be delivered for Fresultant within the range of the investigated parameters

Summary

Introduction

Publisher’s Note: MDPI stays neutral with regard to jurisdictional claims in published maps and institutional affiliations. Machinability of hardened materials, and especially of hardened steels, is an aspect that is widely studied, since these materials are repeatedly used by the manufacturing industry to produce standardized machine elements such as bearings. The availability of established models for the machining of such materials in a broad range of cutting conditions is crucial. Use of finite element (FE) models is one way to achieve this goal. Despite the fact that FE modelling can be time-consuming, even with the use of modern computers, it is a method that provides multiple benefits to the researcher such as visualization of the experimental process, good approximation of complex problems, adaptability and the ability to yield multiple output data [1]

Methods

Results

Conclusion