Development of three-dimensional finite element model to calculate the turning processing parameters in turning operations

Abstract

Metal turning is a widely used process in metal removal operations. These operations are investigated experimentally, analytically and numerically. Since these operations have a very complex structure, it is quite difficult to solve them analytically. Experimental method is both costly and time-consuming. However, this complex structure can be solved easily by using numeric analyses based on finite element method (FEM). Modeling metal turning processes in three dimensional (3D) by using FEM may be useful for validation of experimental studies and it can be also considered as a reliable tool for new metal removal techniques. Parameters such as cutting tool stresses, cutting forces, tool wears, cutting tool temperature, workpiece temperature, chip temperature, cutting tool–chip interface temperature, residual stresses and shear angle, which are difficult to determined analytically and experimentally during turning processes, can be easily identified by using simulation tools based on FEM on the computer. In this study, a 3D FEM model and software were developed for turning processes. Mechanical power, heat transfer coefficients and friction coefficient at the tool–chip interface can be calculated for numeric analyses by using the software developed. A comparison was performed for temperature, main cutting force and thrust force obtained from experimental results and numerical analyses. It can be said that the 3D FEM model gives reasonable results with experimental results in view of temperature, main cutting force, thrust force, shear angle.