Modeling and Simulation of Temperature Generated on Workpiece and Chip Formation in Orthogonal Machining

Experimental investigation in machining operation for the temperature generated on workpiece, chip formation and cutting tool are difficult, time consuming and costly to carry out. Machining simulation using FEM software is an alternative. This paper presents a simulation study of temperature generated on workpiece and chip formation for various combinations of tool geometries (rake angle and clearance angle). Ductile cast iron FCD500 grade was used as material workpiece, and uncoated carbide tools with code number DNMA432 were used as cutting tool. Twelve designs of carbide cutting tools with various combination of rake angle (15, 20, and 30 deg) and clearance angle (5, 7, 8 and 9 deg) were designed. The nose radius of the cutting tool was kept constant at 0.4 mm. Machining parameters of cutting speed, feed rate and dept of cut (DOC) were kept constant at 200 m/min, 0.35 mm/rev and 3 mm respectively. Using a commercial software package Deform-3D, twelve orthogonal machining simulations were carried out to analyze the effect of tool geometries on temperature generated and chip formation. The results show that by increasing the rake angle, the machining performance is improved due to the low temperature generated on the machined surface, as well as low cutting force, stress, and strain. On the other hand, increasing/decreasing the clearance angle, does not significantly affected the cutting force, stress, and strain, consequently it does not affected the temperature generated. For the chip formation, the highest temperature occurred in the sliding region due to the work piece material adheres to the cutting tool and shear occurs within the chip, the frictional force is very high; consequently heat is generated from this sticking regio

Prediction of Turning Performance in Various Machining Parameter Using FEM

In recent years, the applications of finite element method (FEM) in metal cutting operations have proved to be effective in studying the cutting process and manufacturing process. The simulation result is useful for both researchers and tool makers to optimize the cutting process by designing new tools. Simulation and modelling were performed in two-dimensional and threedimensional for designing the new component prior to fabricating. These are very useful for reducing time and cost consumption in designing automotive parts. The FEM simulation just only requires computational tool and FEM simulation package. The present work aims to predict of performance three-dimensional orthogonal of cutting operations using FEM software (Deform-3D). Some important information such as cutting force, stress, strain and generated temperature during machining process were studied and analysed. Orthogonal cutting simulations were conducted to study the effect of cutting speed, feed rate and depth of cut on the cutting force, the effective-stress, strain and generated temperature in turning process. FCD 500 (ductile cast iron) was used as the work material and cutting tool was DNMA 432 (uncoated carbide tool, SCEA = 0; BR = -5; SR = -5 and radius angle 55o). The cutting parameters varied were cutting speed (100 m/min, 150 m/min and 200 m/min), feed rate (0.1, 0.25 and 0.4 mm/rev), and depth of cut (DOC) (0.3, 0.6 and 0.9 mm). The performance was showed by the simulation results that show by increasing the cutting speed, it causes decreasing in cutting force, effective stress and strain, but the generated temperature during the chip formation process increases. High value of feed rate resulted in bigger cutting force, stress, strain and generated temperature. In addition, bigger cutting force and high generated temperature occurred at high depth of cut

Machining Simulation of AISI 1045 and Carbide Tool Using FEM

In recent years, the applications of finite element method (FEM) in metal cutting operations have proved to be effective in studying the cutting process and chip formation. In particular, the simulation results can be used for both researchers and machine tool makers to optimize the cutting process and designing new tools. Many researches were done on two-dimensional simulation of cutting process because the three-dimensional versions of FEM software required more computational time. The present work aims to simulate three-dimensional orthogonal cutting operations using FEM software of Deform-3D. Orthogonal cutting finite element model simulations were conducted to study the effect of cutting speed on effective-stress, strain and temperature in turning process. AISI 1045 was used as work material and cutting tool was TNMA 332 (uncoated carbide tool, SCEA = 0; BR = -5; SR = -5 and radius angle 60o). The emphasis on the designed geometries are limited to the changes in the cutting speed between 100 m/min and 450 m/min. The machining parameters of feed rate and depth of cut were kept constant at 0.35 mm/rev and 0.3 mm respectively. The simulation results show that by increasing the cutting speed causes a decrease in cutting force and effective-strain. On the other hand, increasing in cutting speed will increase effective -strain and temperature of the chip formed

Application of FEM in Investigating Machining Performance

The two biggest problems that often experienced in machining cast iron are poor machinability and high hardness. Up to now, many researchers have investigated machining performance and how to find optimum condition in machining ductile cast iron. This study aims to investigate the machining performance of ductile cast iron and carbide cutting tool using FEM. Performances were evaluated by changing the cutting tool geometries on the machining responses of cutting force, stress, strain, and generated temperature on the workpiece. Deform-3D commercial finite element software was used in this study. Ductile cast iron FCD 500 grade was used as the work piece material and carbide insert DNMA432 type with WC (Tungsten) was used for the cutting tool. The effects of rake and clearance angles were investigated by designing various tool geometries. Various combination of carbide insert geometries were designed using Solid Work to produce +15, +20 and +30 deg for rake angle and 5, 7, 8 and 9 deg for clearance angle. Machining condition for the simulations were remained constant at cutting speed of 200 m/min, feed rate of 0.35 mm/rev, and depth of cut of 0.3 mm. The results of effective-stress, strain and generated temperature on both chip and material surface were analysed. The results show that by increasing the rake angle (α), it will improves the machining performance by reducing the cutting force, stress, strain and generated temperature on surface of workpiece. But, by increasing the clearance angle (γ), it will not affect much to the cutting force, stress, strain and generated temperature on chip

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

Evaluation of Thrust Force in Drilling of Woven Kenaf Fiber Reinforced Epoxy Composite Laminates / Suhaily Mokhtar...[et al.]

Drilling or creating holes in composite parts are a necessary and sensible task, preponderantly for facilitating the assembly of joints. Within the present investigation, the drilling operation of natural fiber reinforced thermosetting (epoxy) composite laminates was assessed in terms of the drilling force. This study conjointly incorporated the employment of a Box Behnken Design with 17 test runs within which machining parameters corresponding to the cutting speed (20 – 70 m/min), feed rate (0.1 – 0.3 mm/rev) and drill sizes (6,9 and 12 mm) were taken as input variables. The consequences of two different types of tool materials (non-coated HSS and non-coated carbide) were conjointly evaluated within the study. The Response Surface Methodology (RSM) was used to analyze the thrust force when drilling woven kenaf fiber reinforced composites with non-coated HSS and non-coated carbide drill bits. Based on the study, the drill size and feed rate were found to be the most significant factors that influenced the thrust force in both of the cutting tool materials used in the study. In addition, the non-coated carbide drill bit shows a better performance of producing minimal thrust force values during the drilling of woven kenaf fiber reinforced composite laminates

Study on drilling induced delamination of woven kenaf fiber reinforced epoxy composite using carbide drills

In this research study, it presents the influences of drilling parameters on the delamination factor during the drilling of woven kenaf fiber reinforced epoxy composite laminates when using the carbide drill bits. The purpose of this study is to investigate the influence of drilling parameters such as cutting speed, feed rate and drill sizes on the delamination produced when drilling woven kenaf reinforced epoxy composite using the non-coated carbide drill bits. The damage generated on the woven kenaf reinforced epoxy composite laminates were observed both at the entrance and exit surface during the drilling operation. The experiments were conducted according to the Box Behnken experimental designs. The results indicated that the drill diameter has a significant influence on the delamination when drilling the woven kenaf fiber reinforced epoxy composites

Machinability study on milling kenaf fiber reinforced plastic composite materials using the design of experiments

The surface roughness (Ra) and delamination factor (Fd) of a milled kenaf reinforced plastic composite materials 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 composite materials. The composite panels were fabricated using vacuum assisted resin transfer moulding (VARTM) method. A full factorial design of experiments was use 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 that 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 (Ra) and delamination factor (Fd) of milled kenaf reinforced plastic composite materials. The spindle speed and feed rate contributed the most in affecting the surface roughness and the delamination factor of the kenaf composite materials.

A Study on Parameter Optimization of the Delamination Factor (Fd) in Milling Kenaf Fiber Reinforced Plastics Composite Materials Using DOE Method / Azmi Harun...[et al.]

Kenaf is known by its scientific name, Hibiscus cannabinus, which is similar to jute and cotton, and is also a warm-season annual fibrous crop. In the past, it was used to make sackcloth, and its twine was used to manufacture rope. Kenaf is also used as a cordage crop. A machine’s surface quality normally depends for its reliability in the service application. The machining process changes the mechanical and chemical properties of individual constituents used for the composite. The objectives of this research are to study the effects of milling parameters and to determine the optimum conditions for a range of milling parameters to minimize the delamination factor (Fd) in milling kenaf fiber-reinforced plastic composite using the Taguchi Method. The Taguchi Method L8 (23) design was used to conduct a non-sequential experiment. The experimental results were analyzed using the Minitab 16 software. A study was carried out to investigate the relationship between the milling parameters, and their effects on the kenaf reinforced plastic. The composite panels were fabricated using the vacuum assisted resin transfer molding (VARTM) method. This study determined that the optimum parameters for the minimum delamination factor were a cutting speed of 16 Vm/min, a feed rate of 0.1 mm/tooth, and a depth of cut of 2.0 mm. The feed rate and cutting speed made the biggest contributions to the delamination factor (Fd). The use at high spindle speeds and low feed rates led to minimized delamination factor (Fd) during the milling of kenaf reinforced plastic composite materials

In vitro study of antifungal activity of Entada spiralis Ridl. crude extract against dermatophytes of superficial skin disease

The antifungal activity of crude extracts from the stem bark of Entada spiralis was evaluated in vitro against human dermatophytes by disc diffusion method. Three types of human dermatophytes, known as Trichophyton mentagrophytes, Microsporum gypseum, Trichophyton tonsurans and one non-dermatophyteCandida glabrata, were tested against petroleum ether, ethyl acetate and methanol crude extracts of the E. spiralis. Results revealed that all dermatophytes were susceptible towards all tested crude extracts, whereas, the non-dermatophyte showed resistance to all the extracts. M. gypseum was found to be most susceptible towards petroleum ether extract (400mg/ml), with a zone of inhibition of 16 mm. The ethyl acetate and methanol crude extracts (400mg/ml each) exhibited highest activity against T. tonsurans with inhibition zones of 12.7 mm and 11.5 mm, respectively. Nystatin was used as the standard antifungal drug in all experiments and served as the positive control. All these results suggested that the petroleum ether crude extract was the most active extract against all tested dermatophytes except for C. glabrata. Based on these current findings, it can be concluded that the stem bark extracts of E. spiralis have promising antifungal activities and can be used as a potent antifungal drug against certain dermatophytes