Effects of single point cutting tool materials on tool work interface and cutting performance using FEA

Abstract

The purpose of this work is to come to a conclusion about the best cutting tool material for mild steel machining using a single point cutting tool. In a single point cutting tool, the geometry of cutting tool affects the quality of manufacturing process. The chip formation process involves plastic deformation during which large strains and strain rates are developed by shear deformation of work material immediately ahead of tool. Mild steel (low carbon steel) is used for machining and insert materials for single point cutting tool are of cubic boron nitride (CBN-grade tnma160408) (used for both finishing and roughing), cermet insert (for finishing), carbide insert (for roughing). For determining the best cutting tool material among three above mentioned cutting tools, the cutting performance is observed by machining of mild steel done in the machine shop. For the improvement of cutting performance, the knowledge of cutting forces, temperature at the tool-work interface and time of cutting with good accuracy is essential which is done by FEA analysis using ABAQUS software [1]. Because of nature and constants of the metal cutting and insert used, heat is generated during the chip formation process as a result of plastic deformation, heat conduction and friction. The heat influences chip shape, tool wear, surface finish and cutting forces, which also effects the hardness of insert material before and after the turning process on work-piece. Various effects of single point cutting tool materials on tool work interface and cutting performance are studied using FEA.