3D Numerical Investigation of Thermally Assisted High Efficiency Ductile Machining of Brittle Materials

Abstract

This study investigates the effects of four different variables (initial workpiece temperature, side rake angle, edge radius/feed rate, and nose radius/depth of cut) on ductile regime machining of a bioceramic material known as nanohydroxyapatite (nano-HAP) using 3D numerical simulation. AdvantEdge FEM Version 5.9 is used to conduct the simulation of turning of the nano-HAP. Tecplot 360 is used to analyze the results of the simulations. Because the workpiece is thin, the entire workpiece is set to a uniform initial temperature to simulate laser preheating of the material. By varying initial workpiece temperature, rake angle (side rake angle), edge radius, and nose radius, the effects of these operating conditions on pressure distribution (critical feed) are investigated. It is found that critical feed increases as initial workpiece temperature increases, and as negativity of rake angle increases. For the edge radius, the critical feed appears to increase with this parameter. For the nose radius, critical feed seems to be independent of it.