Investigation of Stress Formation and Wear Effect of Tool by Finite Element Simulation

Aung Kyaw Sein^1, , Ei Ei Htwe¹ and Nyein Aye San¹

¹Department of Mechanical Engineering, Mandalay Technological University, Myanmar

Cite this paper:
Aung Kyaw Sein, Ei Ei Htwe and Nyein Aye San. Investigation of Stress Formation and Wear Effect of Tool by Finite Element Simulation. American Journal of Mechanical Engineering. 2015; 3(5):147-154. doi: 10.12691/ajme-3-5-2

Abstract

The paper presents aspects related to simulation of metal cutting for titanium and its alloys. Detailed study on progression and wear mechanism at the cutting edge of carbide tools were carried out at cutting speed of 30, 60 and 90 m/min, feed rate of 0.2 mm/rev. Firstly, milling finite element model is given based on orthogonal cutting principle, and then the influence laws of cutting parameters on chip formation are analyzed by using different simulation parameters. For simulations, the software based on finite element method DEFORM 2D was used. Machining simulations were conducted using Ti6Al4V and uncoated carbide for workpiece and tool material respectively. DEFORM 2D, a widely used software tool employed for modelling and simulating the orthogonal machining process with different cutting speeds and feed rates. The pattern of wear progression on the flank face of the carbide tools consist of three stages for all the cutting speed simulated. Wear mechanism such as abrasive and adhesive wear were observed on the flank face. Crater wear due to diffusion was also observed on the rake race. The flank wear results most commonly from abrasion on the cutting edge of the tool. The maximum land width is used as an indication of the extent of the flank wear. The severity of the flank wear increases until a critical point is reached. Abrasion and deformation resistance of the tool material can be increased in order to minimize the flank wear. In order to investigate the cutting tool stress analysis, FEM is conducted with ANSYS software. The overall objective of this study is to develop a methodology to predict the tool wear evaluation and stress formation in orthogonal cutting.

Keywords:
feed rate cutting speed titanium tool wear stress formation

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