Design and analysis on textured cutting tool

Abstract

Cutting tool plays a major role in manufacturing process to reduce cost and machining time. Various number of researches had been conducted to optimize machining process and to find a way to extend the life of the cutting tool. To improve the process quality, the surface texturing is also performed on the cutting tool. In this paper, the machinability of textured tungsten carbide cutting tool for turning aluminum alloy is proposed. The texture pattern used in parallel stripes and vertical stripes on the flank of the cutting tool. The simulations of the texture pattern were engraved on the tool using Abaqus/CAE 6.14 software chip formation simulation had been done. Boundary conditions for the work is defined as displacement and rotation and the velocity is defined as 0.2 m/s. The meshing of the part and work is done in square mesh pattern and the discretization rate is 0.0005. From the analysis, the chip flow direction and the shear zone are discussed in detail. Subsequently, the energy developed on machine the material has been evaluated with the results of cutting force. The maximum cutting force developed in the plain cutting tool is 1.468 N. however, for the textured cutting tool has 1.207 N for horizontal texture tool and 3.249 N vertical textured cutting tool. It indicates that the horizontal has a built – up edge nature and supports to shear the material conveniently than the other two conditions. In addition, the stress induced during the machining process is also compared for interpretation. Thus, the inference is made to justify that the tool life is increased when surface texturing is done compared to the tool life for non-textured tool.