Experimental Investigation and Numerical Prediction of the Effects of Cutting Tool Geometry During Turning of AISI 316L Steel

Amor Benmeddour

doi:10.3311/ppme.16844

Abstract

In this work, a numerical and an experimental study aimed to gain a better understanding of the impact of tool geometry such as (rake angle and cutting edge radius) on the temperature distribution and residual stresses in machining surface of AISI 316L stainless steel have been presented. To evaluate the experimental results, various experimental equipment was used, such as a conventional lathe to carry out the machining operations, the cutting force was measured using a Kistler dynamometer and X-ray diffraction technique was employed for determination of the residual stresses distribution on the machined surfaces. In addition, A thermo-mechanically coupled finite element (FE) analysis for cutting process is developed through ABAQUS code to predict the temperature distribution and residual stresses using an Arbitrary Lagrangian-Eulerian (ALE) approach. An inverse identification method has been used to determine the adequate Johnson-Cook (JC) material model parameters to obtain a good correlation between the cutting force measurements and numerical one. The FE model was then validated by comparison of the numerical results of residual stresses with experimental measurements for different tool geometries, which revealed a reasonable agreement.

Highlights

In the machining process, the quality of the produced parts are strongly affected by the state of the induced residual stresses, which are influenced by numerous parameters such as depth of cut, cutting speed, feed rate and the geometrical features of the tool
In the last few years, the numerical models based on a finite element model (FEM) have been widely employed by many researchers for simulations of metal cutting process because of their capability to furnish predictions for several parameters of the process such as cutting forces, temperatures and residual stress in the workpiece and chip morphology which can serve out to optimize metal cutting processes and improve the design of the cutting tool, increase the productivity and minimize the machining cost [4, 9,10,11,12,13,14,15,16,17]. because of the important role that the cutting tool geometry plays on the performance of machining operations, the influence of tool geometry on machinability has acquired considerable attention in the scientific literature
The current model has been validated by comparison with numerical prediction of residual stresses and experimental results, the capability of the model to predict both temperature and the induced residual stress field is demonstrated for diverse cutting angles and cutting edges radius

Summary

Introduction

The quality of the produced parts are strongly affected by the state of the induced residual stresses, which are influenced by numerous parameters such as depth of cut, cutting speed, feed rate and the geometrical features of the tool. In the last few years, the numerical models based on a FEM have been widely employed by many researchers for simulations of metal cutting process because of their capability to furnish predictions for several parameters of the process such as cutting forces, temperatures and residual stress in the workpiece and chip morphology which can serve out to optimize metal cutting processes and improve the design of the cutting tool, increase the productivity and minimize the machining cost [4, 9,10,11,12,13,14,15,16,17]. Yen et al [11] studied the effect of tool geometry on machining process using a finite element model to optimize the design of tool edges. A convective heat transfer coefficient of 20 W/m2.k is used and radiation has been neglected

Johnson-Cook constitutive model

Findings

Conclusions