FEM simulation for determining suitable parameters for dimple structure fabrication in turning process

Abstract

Surface texturing in the form of dimples for mechanical components is very important in enhancing those tribological properties which are closely associated to wear and friction. This paper presents the application of Third Wave AdvantEdge software in identifying the turning parameters for dimple structure fabrication. Approximately 20 ranges of cutting parameters of speed and feed rate were tested to obtain the cutting force vs. the length of cut to assist in the rough estimation of the size of the dimple structure before the actual machining was performed. In addition, a simulation using a low dynamic frequency of 15-25 Hertz was carried out in order to evaluate the ability and stability of the vibration-assisted tooling that had been developed in-house. The shape of the cutting force graph obtained from the simulation indicated that the machining parameters of cutting speed of 7-9 m/min, feed rate of 0.4-0.6 mm/rev and depth of cut of 0.01-0.05 mm were found to be suitable for the fabrication of dimples on A3xx casting aluminium alloy.