Finite Element Analysis of The Influence of Edge Roundness on the Stresses and Cutting Forces for Ceramic Cutting Tools
Keywords:
Ceramic, Edge radius, Finite elementAbstract
This work summarizes the effect of edge round preparation for three types of ceramic cutting tool materials (Al2O3/ZrO2, Al2O3/ TiC, Si3N4/Y2O3) upon cutting forces and stress distribution on the cutting tool in orthogonal cutting as determined with Finite Element Method simulations. The results obtained from this study provide a fundamental understanding of the process mechanics for cutting with realistic cutting tool edges and may assist in the optimization of tool edge design. These results compare with other previously published papers and showed a good agreement. It is also proved, that for every cutting condition and tool material, there is an optimum geometry. The material of ceramic cutting tools proved, that it has been good in performance comparing with other previously published papers.
Downloads
References
Cho, S. S., Komvopoulos, K., "Wear Mechanisms of Multi-Layer Coated Cemented Carbide Cutting Tools", Journal of Tribology, Vol.119,pp 8-17, 1997.
Erik Oberk, Franklin D.Jones, Holbrook L.Horton, and Henry H.Ryffel, "Machineryُ s Handbook 28th Edition", Industrial Press Inc., New York, 2008.
Roy J.Schimmel, William J. Endres. and Robin Stevenson, "Application of an Internally Consistent Material Model to Determine the Effect of Tool Edge Geometry in Orthogonal Machining", Transactions of the ASME, Vol.124, 536-543, 2002.
Roy J.Schimmel, William J. Endres, and Jairam Manjunathaiah, "Edge Radius Variability and Force Measurement Considerations" Transactions of the ASME, Vol.122, pp 590-593, 2002.
Ozel T., Tsu-Kong Hsu, and Zeren E.," Effects of Cutting Edge Geometry, Workpiece Hardness, Feed Rate and Cutting Speed on Surface Roughness and Forces in Finish Turning of Hardened AISI H13 Steel" , www.rci.rutgers.edu,.2004.
Jeffery D.T., and Shreyes N.M., "Effect of Cutting Edge Geometry and Workpiece Hardness on Surface Residual Stresses in Finish Hard Turning of AISI 52100 Steel", Transactions of ASME, Journal of Manufacturing Science and Engineering, Vol.122, No.4 642-649,2000 .
Jeffery D.T., and Shreyes N.M., "Effect of Tool Edge Geometry on Workpiece Subsurface Deformation and Through Thickness Residual Stresses for Gard Turning of AISI 52100 Steel", Journal of Manufacturing Processes, Vol.2, No.4, 2000.
Kalhori V., "Modelling and Simulation of Mechanical Cutting", Ph.D., Thesis, University of Lulea Tekniska, 2001.
Astakhov V.P., and Outeiro J.C., "Modeling of the Contact Stress Distribution at the Tool-Chip Interface", Proceeding of The CIRP International Workshop of Modeling of Machining Operations, ENSAM, CLuny, France, May 2004.
Ozel T., and Zeren E.,"Finite Element Analysis of The Influence of Edge Roundness on The Stress and Temperature Fields Induced by High Speed Machining",Rytgers University, Piscataway, New Jersey USA, 2003.
Altan T., "Modeling of Metal Cutting Using FEM", ERC/NSM, The Ohio State University, January 2003.
Altan T., Y.C. Yen, and Anurag J.," A Finite E lement Analysis of Orthogonal Machining Using Different Tool Edge Geometries", ERC/NSM, The Ohio State University Columbus, 2002.
Altan T., Y.C. Yen, Hamdi H., and Rech J., " Influence of Cutting Edge Radius of Coated Tool on Chip Formation in Orthogonal Cutting of Alloy Steel", ERC/NSM, The Ohio State University, May 2004.
T.Keven Chou, and Hui Song, "Hard Turning with Different Nose-Radius Ceramic Tools", Society of Manufacturing Engineers, www..sme.org, 2001.
Honglee T., "An Experimental and Theoretical Investigation for The Machining of Hardened Alloy Steels", Ph.D., Thesis, University of New South Wales, April 2007.
Aabid M., "finite element simulation of chip formation and comprison with experiment", PhD., Thesis, University of Technology, 2002.
Published
How to Cite
Issue
Section
Copyright (c) 2009 Suha K. Shehab
This work is licensed under a Creative Commons Attribution 4.0 International License.
