Abstract
For qualitative prediction of chip morphology and quantitative prediction of burr size, 2D and 3D finite element (FE) based turning models have been developed in this paper. Coupled temperature-displacement machining simulations exploiting the capabilities of Abaqus® with a particular industrial turning insert and a newly proposed geometrical version of this insert have been performed. Limitations of 2D models in defining the chip morphologies and surface topologies have been discussed. The phenomenological findings on the Poisson burr (Side burr) formation using 3D cutting models have been highlighted. Bespoke geometry of the turning insert has been found helpful in reducing the Poisson burr formation, as it reduces the contact pressures at the edges of tool rake face-workpiece interface. Lower contact pressures serve to decrease the material flow towards workpiece edges (out of plane deformation). In contrast, higher contact pressures at tool rake face-workpiece interface lead to more material flow towards workpiece edges resulting in longer burr. Simulation results of chip morphologies and cutting forces for turning an aluminum alloy A2024-T351 have been compared with the experimental ones. Finally, it has been concluded that the newly proposed geometry of the insert not only decreases the burr but also helpful in lessening the magnitude of tool-workpiece initial impact.
Highlights
Researchers and production engineers are well aware of the fact that better comprehension of the physics of the cutting phenomenon can be beneficial in increasing the machining efficiency
To improve the comprehension of the cutting phenomenon the results of the orthogonal turning simulations have been discussed in the present section. 2D and 3D numerical simulations for VC = 800 m/min, f = 0.3 and 0.5 mm/rev, aP = 4 mm with an industrial turning tool insert geometry have been performed
Comparison of 2D and 3D numerical chips have shown that 2D models predict the chip morphology and related information on a section which passes through middle of the workpiece cutting depth aP
Summary
Researchers and production engineers are well aware of the fact that better comprehension of the physics of the cutting phenomenon can be beneficial in increasing the machining efficiency. Latter, this can be achieved by suitable selection of cutting parameters, insert geometries, cutting conditions and machine tools, etc. The role of finite elements, numerical methods and techniques has been vital in this context. In this continuation to improve the comprehension of cutting and eventually to increase the machining efficiency, the study presents 2D and 3D FE based orthogonal turning models. The effects of the geometries of the aforesaid inserts on chip morphology and side burr formation have been discussed
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