Article: Numerical study on the impacts of tool edge geometry and cutting conditions in orthogonal machining of AISI 1045 steel Journal: International Journal of Machining and Machinability of Materials (IJMMM) 2023 Vol.25 No.3/4 pp.209 - 242 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. Inderscience Publishers - linking academia, business and industry through research

Title: Numerical study on the impacts of tool edge geometry and cutting conditions in orthogonal machining of AISI 1045 steel

Authors: Mohamed El Wazziki

Addresses: Department of Mechanical Engineering, École de Technologie Supérieure (ÉTS), 1100 Notre-Dame Street West, Montréal, QC H3C-1K3, Canada

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.

Keywords: tool edge preparation; orthogonal cutting; numerical simulation; analysis of variance; ANOVA.

DOI: 10.1504/IJMMM.2023.136037

International Journal of Machining and Machinability of Materials, 2023 Vol.25 No.3/4, pp.209 - 242

Received: 10 May 2022
Accepted: 06 Aug 2022
Published online: 12 Jan 2024 *

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Title: Numerical study on the impacts of tool edge geometry and cutting conditions in orthogonal machining of AISI 1045 steel

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