Abstract
The present study investigated the performance of three ceramic inserts in terms of the micro-geometry (nose radius and cutting edge type) with the aid of a 3D finite element (FE) model. A set of nine simulation runs was performed according to three levels of cutting speed and feed rate with respect to a predefined depth of cut and tool nose radius. The yielded results were compared to the experimental values that were acquired at identical cutting conditions as the simulated ones for verification purposes. Consequently, two more sets of nine simulations each were carried out so that a total of 27 turning simulation runs would adduce. The two extra sets corresponded to the same cutting conditions, but to different cutting tools (with varied nose radius). Moreover, a prediction model was established based on statistical methodologies such as the response surface methodology (RSM) and the analysis of variance (ANOVA), further investigating the relationship between the critical parameters (cutting speed, feed rate, and nose radius) and their influence on the generated turning force components. The comparison between the experimental values of the cutting force components and the simulated ones demonstrated an increased correlation that exceeded 89%. Similarly, the values derived from the statistical model were in compliance with the equivalent FE model values due to the verified adequacy.
Highlights
Turning is one of the most widely used machining operations in industry
An early example is the work of Guo and Liu [18], who developed a general practical explicit 3D finite element analysis (FEA) model for the analytical purposes of AISI-52100 hard turning with the use of polycrystalline cubic boron nitride (PCBN) inserts
The present paper presented a 3D FE model for the hard turning of AISI-4140 as well as a prediction model for the resultant machining force, based on statistical methods
Summary
Turning is one of the most widely used machining operations in industry. In particular, turning of hardened steel is an indispensable part in a modern manufacturing framework. AISI-4140 is preferred for the production of many typical mechanical parts such as gears, shafts, and bearings [1] For these reasons, a number of studies exist in the literature that investigate various aspects that occur during the machining of hardened steel [2,3,4,5,6]. An early example is the work of Guo and Liu [18], who developed a general practical explicit 3D finite element analysis (FEA) model for the analytical purposes of AISI-52100 hard turning with the use of polycrystalline cubic boron nitride (PCBN) inserts. Magalhães et al [23] presented a finite element (FE) model for hard turning with PCBN inserts prepared with multi-chamfered edges and examined the effects on tool wear and residual stresses. After validating the FE model, a statistical model based on the response surface methodology (RSM) was developed
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