Effect of Rake Angle on Stress, Strain and Temperature on the Edge of Carbide Cutting Tool in Orthogonal Cutting Using FEM Simulation

Demand for higher productivity and good quality for machining parts has encourage many researchers to study the effects of machining parameters using FEM simulation using either two or three dimensions version. These are due to advantages such as software package and computational times are required. Experimental work is very costly, time consuming and labor intensive. The present work aims to simulate a three-dimensional orthogonal cutting operations using FEM software (deform-3D) to study the effects of rake angle on the cutting force, effective stress, strain and temperature on the edge of carbide cutting tool. There were seven runs of simulations. All simulations were performed for various rake angles of -15 deg, -10 deg, -5 deg, 0 deg, +5 deg, +10 deg, and +15 deg. The cutting speed, feed rate and depth of cut (DOC) were kept constant at 100 m/min, 0.35 mm/rev and 0.3 mm respectively. The work piece used was ductile cast iron FCD500 grade and the cutting tool was DNMA432 series (tungsten, uncoated carbide tool, SCEA = 0; and radius angle 55 deg). The analysis of results show that, the increase in the rake angle from negative to positive angle, causing the decrease in cutting force, effective stress and total Von Misses strain. The minimum of the cutting force, effective stress and total Von Misses strain were obtained at rake angle of +15 deg. Increasing the rake caused higher temperature generated on the edge of carbide cutting tool and resulted in bigger contact area between the clearance face and the workpiece, consequently caused more friction and wear. The biggest deformation was occurred in the primary deformation zone, followed by the secondary deformation zone. The highest stress was also occurred in the primary deformation zone. But the highest temperature on the chip usually occurs in secondary deformation zone, especially in the sliding region, because the heat that was generated in the sticking region increased as the workpiece was adhered by the tool and later it was sheared in high frictional force.

Study on machinability effect of surface roughness in milling kenaf fiber reinforced plastic composite (unidirectional) using response surface methodology

The surface roughness factor (Ra) of a milled kenaf reinforced plastic are depending on the milling parameters (spindle speed, feed rate and depth of cut). Therefore, a study was carried out to investigate the relationship between the milling parameters and their effects on a kenaf reinforced plastic. The composite panels were fabricated using vacuum assisted resin transfer molding (VARTM) method. A full factorial design of experiments was used as an initial step to screen the significance of the parameters on the defects using Analysis of Variance (ANOVA). If the curvature of the collected data shows significant, Response Surface Methodology (RSM) is then applied for obtaining a quadratic modelling equation which has more reliable in expressing the optimization. Thus, the objective of this research is obtaining an optimum setting of milling parameters and modelling equations to minimize the surface roughness factor (Ra) of milled kenaf reinforced plastic. The spindle speed and feed rate contributed the most in affecting the surface roughness factor (Ra) of the kenaf composite

Effect of Rake Angle on Stress, Strain and Temperature on the Edge of Carbide Cutting Tool in Orthogonal Cutting Using FEM Simulation

Demand for higher productivity and good quality for machining parts has encourage many researchers to study the effects of machining parameters using FEM simulation using either two or three dimensions version. These are due to advantages such as software package and computational times are required. Experimental work is very costly, time consuming and labor intensive. The present work aims to simulate a three-dimensional orthogonal cutting operations using FEM software (deform-3D) to study the effects of rake angle on the cutting force, effective stress, strain and temperature on the edge of carbide cutting tool. There were seven runs of simulations. All simulations were performed for various rake angles of -15 deg, -10 deg, -5 deg, 0 deg, +5 deg, +10 deg, and +15 deg. The cutting speed, feed rate and depth of cut (DOC) were kept constant at 100 m/min, 0.35 mm/rev and 0.3 mm respectively. The work piece used was ductile cast iron FCD500 grade and the cutting tool was DNMA432 series (tungsten, uncoated carbide tool, SCEA = 0; and radius angle 55 deg). The analysis of results show that, the increase in the rake angle from negative to positive angle, causing the decrease in cutting force, effective stress and total Von Misses strain. The minimum of the cutting force, effective stress and total Von Misses strain were obtained at rake angle of +15 deg. Increasing the rake caused higher temperature generated on the edge of carbide cutting tool and resulted in bigger contact area between the clearance face and the workpiece, consequently caused more friction and wear. The biggest deformation was occurred in the primary deformation zone, followed by the secondary deformation zone. The highest stress was also occurred in the primary deformation zone. But the highest temperature on the chip usually occurs in secondary deformation zone, especially in the sliding region, because the heat that was generated in the sticking region increased as the workpiece was adhered by the tool and later it was sheared in high frictional force

Comparison effect of delamination factor (Fd) on unidirectional and woven kenaf fibre reinforced plastic composite materials during milling process [Pembandingan kesan faktor pelekangan (Fd) ke atas bahan komposit plastik bertetulang ekaarah dan bertenun semasa proses pemesinan kisar]

Serabut kenaf merupakan salah satu serabut berasaskan tumbuhan di dalam kumpulan serabut asli yang semakin luas penggunaannya. Serabut kenaf dicampurkan dengan bahan plastik (epoksi) bagi menghasilkan suatu bahan baharu dengan sifat mekanikal yang baik dengan kos pembuatan yang rendah. Bahan kerja ini terbahagi kepada dua jenis iaitu serabut kenaf ekaarah dan serabut kenaf tenunan. Uji kaji ini akan menumpukan kepada pembandingan kesan faktor pelekangan Fd yang terhasil semasa proses pemesinan kisar ke atas bahan komposit tersebut dengan penentuan set parameter mesin yang paling optimum bagi mengurangkan kesan Fd. Uji kaji dijalankan berdasarkan analisis kaedah gerak balas permukaan (RSM) dengan pendekatan reka bentuk Box-Behnken bagi mendapatkan hasil faktor bersandar terhadap sambutan. Faktor yang terlibat adalah kelajuan pemotongan, kadar suapan dan kedalaman pemotongan. Proses pengisaran secara lelurus (lurah) dilakukan bagi melihat kesan Fd yang terhasil dengan menggunakan perkakasan mata alat jenis Keluli Berkelajuan Tinggi (HSS) tidak bersalut hujung rata berdiameter 10 mm. Imej daripada mikroskop menunjukkan bahan komposit serabut kenaf ekaarah menghasilkan faktor pelekangan yang tinggi berbanding kesan ke atas bahan komposit serabut kenaf bertenun. Bagi set parameter optimum pula, bahan kerja serabut kenaf ekaarah ialah kelajuan pemotongan, kadar suapan dan kedalaman pemotongan yang rendah. Manakala bagi bahan kerja serabut kenaf bertenun, set parameter optimum adalah kelajuan pemotongan yang rendah dengan kadar suapan dan kedalaman pemotongan yang tinggi

TRIZ approach for machining process innovation in cryogenic environment

This paper presents the utilisation of TRIZ approach in machining process of AISI 4340 in cryogenic environment which lead to product improvement in turning process. The machining study is carried out in two stages; FEM simulation for finding the optimum condition and machining experiment to visualise the product improvement that involved plastic deformation. The simulation result revealed that at moderate to high cutting speed, high feed rate and high depth of cut will result in high temperature that enable for the change in phase of AISI 4340 from retained austenite to fully martensite. A sample from machining experiment at optimum cutting condition found that the microstructure changes beneath the machined until at the depth of ∼7 μm with high hardness to 8,500 N/mm2 Martens hardness at the machined surface. This hardness is equivalent to the hardness obtained in conventional case hardening process that is required after the machining of AISI 4340 in their application as automotive engine parts in order to enhance these parts in their service lives. This study reveals that the TRIZ approach helps to systematically analyse the various outcomes in this study started with process limitation, problem identification, axiomatic and Su-field analysis

The Application of I-kazTM-based Method for Tool Wear Monitoring Using Cutting Force Signal

AbstractTool wear monitoring is important in machining industries for controlling the quality of machined parts that helps to improve the productivity. To date, many monitoring system methods are developed by utilizing various signals, and cutting force is one of the signals in machining process that has been widely used for tool wear monitoring. This paper presents the application of I-kaz based method to analyze the cutting force signal for monitoring the status of tool wear in turning process. Experiments were carried out by turning hardened carbon steel, and cutting force signals were measured by two channels of strain gauges that were mounted on the surface of tool holder. In this study, I-kaz 2D is one of the derivatives of I-kazTM method that has been utlized to integrate two components of cutting force signals. It differs from the I-kaz method, whereby the signal does not need to be decomposed to three different frequency ranges. The analysis of results using I-kaz 2D and I-kazTM methods, revealed that both methods can be used to determine tool wear progression during turning process and feed force is very significant due to flank wear

Application of ANN in Milling Process: A Review

In recent years the trends were towards modeling of machining using artificial intelligence. ANN is considered one of the important methods of artificial intelligence in the modeling of nonlinear problems like machining processes. Artificial neural networks show good capability in prediction and optimization of machining processes compared with traditional methods. In view of the importance of artificial neural networks in machining, this paper is an attempt to review the previous studies and investigations on the application of artificial neural networks in the milling process for the last decade

Prediction of Surface Roughness When End Milling Ti6Al4V

Surface roughness is considered as the quality index of the machine parts. Many diverse techniques have been applied in modelling metal cutting processes. Previous studies have revealed that artificial intelligence techniques are novel soft computing methods which fit the solution of nonlinear and complex problems like metal cutting processes. The present study used adaptive neurofuzzy inference system for the purpose of predicting the surface roughness when end milling Ti6Al4V alloy with coated (PVD) and uncoated cutting tools under dry cutting conditions. Real experimental results have been used for training and testing of ANFIS models, and the best model was selected based on minimum root mean square error. A generalized bell-shaped function has been adopted as a membership function for the modelling process, and its numbers were changed from 2 to 5. The findings provided evidence of the capability of ANFIS in modelling surface roughness in end milling process and obtainment of good matching between experimental and predicted results

Parameters Affecting the Extraction Process of Jatropha Curcas Oil Using a Single Screw Extruder

The most commonly used technique to separate oil and cake from J. curcas seeds is mechanical extraction. It uses simple tools such as a piston and a screw extruder to produce high pressure, driven by hand or by engine. A single screw extruder has one screw rotating inside the barrel and materials simultaneously flow from the feed to the die zone. The highest oil yield can be obtained by a well-designed oil press as well as finding the optimum conditions for all parameters involved during the extraction process. The influence of the parameters in a single screw extruder was studied using finite element analysis and computational fluid dynamics simulation with ANSYS POLYFLOW. The research focused on predicting the velocity, pressure and shear rate in the metering section that influenced the screw rotational speed and mass flow rate. The obtained results revealed that increasing the screw rotational speed will increase the pressure, velocity and shear rate. Meanwhile, increasing the mass flow rate results in decreasing the pressure while the velocity and shear rate remain constant

Pembandingan kesan faktor pelekangan (Fd) ke atas bahan komposit plastik bertetulang ekaarah dan bertenun semasa proses pemesinan kisar

Serabut kenaf merupakan salah satu serabut berasaskan tumbuhan di dalam kumpulan serabut asli yang semakin luas penggunaannya. Serabut kenaf dicampurkan dengan bahan plastik (epoksi) bagi menghasilkan suatu bahan baharu dengan sifat mekanikal yang baik dengan kos pembuatan yang rendah. Bahan kerja ini terbahagi kepada dua jenis iaitu serabut kenaf ekaarah dan serabut kenaf tenunan. Uji kaji ini akan menumpukan kepada pembandingan kesan faktor pelekangan Fd yang terhasil semasa proses pemesinan kisar ke atas bahan komposit tersebut dengan penentuan set parameter mesin yang paling optimum bagi mengurangkan kesan Fd. Uji kaji dijalankan berdasarkan analisis kaedah gerak balas permukaan (RSM) dengan pendekatan reka bentuk Box-Behnken bagi mendapatkan hasil faktor bersandar terhadap sambutan. Faktor yang terlibat adalah kelajuan pemotongan, kadar suapan dan kedalaman pemotongan. Proses pengisaran secara lelurus (lurah) dilakukan bagi melihat kesan Fd yang terhasil dengan menggunakan perkakasan mata alat jenis Keluli Berkelajuan Tinggi (HSS) tidak bersalut hujung rata berdiameter 10 mm. Imej daripada mikroskop menunjukkan bahan komposit serabut kenaf ekaarah menghasilkan faktor pelekangan yang tinggi berbanding kesan ke atas bahan komposit serabut kenaf bertenun. Bagi set parameter optimum pula, bahan kerja serabut kenaf ekaarah ialah kelajuan pemotongan, kadar suapan dan kedalaman pemotongan yang rendah. Manakala bagi bahan kerja serabut kenaf bertenun, set parameter optimum adalah kelajuan pemotongan yang rendah dengan kadar suapan dan kedalaman pemotongan yang tinggi