Numerical study on the impacts of tool edge geometry and cutting conditions in orthogonal machining of AISI 1045 steel
by Mohamed El Wazziki
International Journal of Machining and Machinability of Materials (IJMMM), Vol. 25, No. 3/4, 2023

Abstract: The present article presents a numerical study of the effects of tool geometries and cutting parameters on temperature, effective stress, chip thickness and tool wear depth during orthogonal cutting of AISI 1045 steel. This study consists to perform different numerical simulation tests using finite elements method on cutting chamfer tool. The important parameters that significantly influence the different studied machining characteristics were identified using analysis of variance (ANOVA). The obtained numerical results showed that the high values of temperature, stress, chip thickness and wear depth were almost obtained for the chamfer widths of (0.35, 0.45) mm. With increasing chamfer angle, there were different fluctuations of all the studied characteristics. In term of combinate influences, for different cutting speeds, the optimum chamfer width of (0.25, 0.35) mm produces respectively minimum and maximum cutting stress, chip thickness and wear depth. For different chamfer angles, cutting temperature, stress, and wear depth increase with increasing feed rate, whereas, maximum chip thickness was found for chamfer angle of 25°. The ANOVA showed that the feed rate, the cutting speed and their interactions influence almost significantly cutting temperature, stress, chip thickness and wear depth.

Online publication date: Fri, 12-Jan-2024

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