High Speed Machining Of AISI Research Articles

Finite Element Modeling of the Effect of Tool Rake Angle on Cutting Force and Tool Temperature during High Speed Machining of AISI 1045 Steel

A finite element model (FEM) of an orthogonal metal-cutting process is used to study the influence of tool rake angle on the cutting force and tool temperature. The model involves Johnson-Cook material model and Coulomb’s friction law. A tool rake angle ranging from 0° to 20° and a cutting speed ranging from 300 to 600 m/min were considered in this simulation. The results of this simulation work are consistent optimum tool rake angle for high speed machining (HSM) of AISI 1045 medium carbon steel. It was observed that there was a suitable rake angle between 10° and 18° for cutting speeds of 300 and 433 m/min where cutting force and temperature were lowest. However, there was not optimum rake angle for cutting speeds of 550 and 600 m/min. This paper can contribute in optimization of cutting tool for metal cutting process.

Finite Element Modelling of the effect of tool rake angle on tool temperature and cutting force during high speed machining of AISI 4340 steel

In this paper, a Finite Element Method (FEM) based on the ABAQUS explicit software which involves Johnson-Cook material model was used to simulate cutting force and tool temperature during high speed machining (HSM) of AISI 4340 steel. In this simulation work, a tool rake angle ranging from 0° to 20° and a range of cutting speeds between 300 to 550 m/min was investigated. The purpose of this simulation analysis was to find optimum tool rake angle where cutting force is smallest as well as tool temperature is lowest during high speed machining. It was found that cutting forces to have a decreasing trend as rake angle increased to positive direction. The optimum rake angle observed between 10° and 18° due to decrease of cutting force as 20% for all simulated cutting speeds. In addition, increasing cutting tool rake angle over its optimum value had negative influence on tool's performance and led to an increase in cutting temperature. The results give a better understanding and recognition of the cutting tool design for high speed machining processes.

Microscopic Observation of White Band within Shear Zone of Chip Produced during High Speed Machining of AISI 1045 Hardness Steel

To study the microstructure of white band is helpful for revealing formation mechanism of serrated chip. This paper investigates the microstructural characteristics of white bandsat primary and second deformation zone within the serrated chips produced during High Speed Machining (HSM) of AISI 1045 hardened steel usingoptical microscope, SEM, TEM, and electron microprobe, X-Ray diffraction. It was found that the white bands within primary and second deformation zone consist of small equiaxed grains which formed due to dynamic recrystallization during adiabatic shear, however, martensitic transformation just only taken place within the white band in second deformation zone. The re-distribution of chemical elements between the composition phases occurred due to the combined effect of adiabatic temperature rise and high speed deformation in formation process of white band. The former is result from adiabatic shear in primary deformation zone during formation of chip, while the latter is caused by the intense shear and friction between tool and chip.

An Investigation into the Microstructure of Adiabatic Shear Banding in AISI 1045 Hardened Steel due to High Speed Machining

Adiabatic shear banding during high speed machining is important to understand material removal mechanisms. This paper investigates the microstructure of adiabatic shear bands (ASBs) in the serrated chips produced during the high speed machining of AISI 1045 hardened steel. Optical microscope, scanning electronic microscope(SEM) and transmission electronic microscope(TEM) were used to explore the microstructural characteristics. It was found that there are two types of adiabatic shear bands. One is the deformed adiabatic shear band composed of a significantly deformed structure generated in a range of low cutting speeds, and the other is the transformed adiabatic shear band composed of very small equiaxed grains generated under high cutting speeds. The results indicated that the deformed band has a tempered martensite structure that formed through large plastic deformation and the transformed band has experienced a dynamic recrystallization process.

Estimating the effect of cutting parameters on surface finish and power consumption during high speed machining of AISI 1045 steel using Taguchi design and ANOVA

The present paper outlines an experimental study to investigate the effects of cutting parameters on finish and power consumption by employing Taguchi techniques. The high speed machining of AISI 1045 using coated carbide tools was investigated. A combined technique using orthogonal array and analysis of variance was employed to investigate the contribution and effects of cutting speed, feed rate and depth of cut on three surface roughness parameters and power consumption. The results showed a significant effect of cutting speed on the surface roughness and power consumption, while the other parameters did not substantially affect the responses. Thereafter, optimal cutting parameters were obtained.