Static & dynamic performance analysis and modal simulations of single point cutting tool

Abstract

Tool manufacturers’ aims to produce quality tools to with stand higher cutting forces, thermal resistivity with increased wear resistance to improve tool life and to produce better surface finish maintaining dimensional accuracy of the finished product. The paper analyses the machining performances of single point cutting tool made from high speed steel and tungsten carbide in dry machining of mild steel and aluminium. Varying cutting speeds, feed rates and depth of cuts were taken into consideration for the experimental performance, using lath tool dynamometer. The data obtained from the experiments are used for the static, modal and steady state dynamic analysis using FEA package ABAQUS solver. From the static analysis, it was found that WC has a higher stiffness and durability as compared to the HSS. The natural frequencies and the mode shapes of the HSS and WC tools were identified and plotted. The analysis showed WC tool has higher natural frequencies as compared to the HSS tool for each of the six mode shapes. The dynamic analysis of the tools showed the deformation was least for WC. The stress induced in WC was found to be around 50% of that of HSS and the factor of safety was almost double to that of HSS. Thus this paper shows that static and dynamic performance analysis of the WC tools is better than the HSS tools.