Abstract
ABSTRACTThe length of tool–chip contact area (Lc) is considered as a considerable parameter in metal cutting process. Mechanical stresses and high temperature at this region may easily lead to abrasion or even breakage of cutting tool. Up to now, several solutions have been presented to overcome these limitations. Using cutting fluids is one of the solutions to reduce friction, stresses, and temperature over this area. This paper presents experimental investigation and finite element simulation of tool–chip interface in hard turning AISI 4140 using TiO2 nanofluids. Nanofluids are newly class of engineering fluids developed by distributing nanometer solid particles in a base fluid. The main reason to use nanofluids in cutting process is to increase heat transfer capabilities and also its tribological attributes. At first, the effects of cutting speed, nanoparticles’ size, and nanofluid concentration on Lc have been experimentally investigated. Then, a numerical model has been developed to simulate the contact area length in case of nanofluids application. Comparing the results with that of the experimental tests shows that TiO2 nanofluids are able to decrease Lc, about 35%, in feed rate of 0.11 mm/rev, nanoparticle size equal to 10 nm, and nanofluid concentration equal to 3.0 wt%.
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