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.

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

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

Uji Kinerja Pengering Surya dengan Kincir Angin Savonius untuk Pengeringan Ubi Kayu (Manihot esculenta)

Abstrak. Ubi kayu merupakan salah satu tanaman yang mengandung karbohidrat. Ubi kayu dapat dikeringkan untuk mendapatkan produk olahan contohnya pembuatan tepung dan gaplek. Pada penelitian ini dilakukan modifikasi pengering surya dengan menambahkan kincir angin savonius sebagai penggerak kipas pada pengering tersebut yang bertujuan untuk memaksimalkan sirkulasi udara didalam ruang pengering. Parameter yang dilakukan diantaranya pengukuran kecepatan udara, distribusi temperatur, kelembaban relatif, iradiasi surya dan pengukuran kadar air. Dengan penambahan kincir angin savonius, kecepatan udara di dalam pengering surya lebih stabil bila dibandingkan dengan kecepatan udara di lingkungan. Temperatur di dalam ruang pengering lebih tinggi dari pada temperatur lingkungan, sedangkan kelembaban relatif di dalam pengering lebih rendah dibandingkan dengan di lingkungan. Hal ini menyebabkan proses pengeringan berlangsung cepat. Nilai iradiasi surya yang didapat berfluktuasi. Iradiasi tertinggi diperoleh pada hari kedua penelitian yaitu 595 W/m2. Kadar air awal ubi kayu yaitu 61,7 %. Kadar air akhir yang diperoleh rak A5 yaitu sebesar 11,7% dan rak B1 yaitu sebesar 12,9% sudah mendekati kadar air yang diharapkan untuk  pembuatan tepung yaitu 12%. Performance of Solar Dryer by Using Savonius Windmill for Cassava (Manihot esculenta) DryingAbstract. Cassava is one of the plants that contain carbohydrates. Cassava can be dried to produce processed products such as cassava flour and “gaplek”. In this research, the solar dryer was modified by adding a savonius windmill as fan drive which aims to maximize the air circulation inside the drying chamber. The observed parameters include air velocity, the distribution of temperature, relative humidity, solar irradiation and the water content. The addition of savonius windmill caused the air velocity in the solar dryer was more stable when compared to the speed of the air in the environment. Moreover, the temperature in the drying chamber was higher than the ambient temperature, while the relative humidity in the dryer was lower than in the environment. As a result, it caused rapid drying process. Solar irradiation values obtained fluctuate. The highest irradiation was obtained on the second day of the study (595 W / m2). The moisture content of the cassava decreased from  61.7% to 11.7% (at A5 rack) and 12.9% (at B1 rack). Those values was approaching the expected flour water content (12% )

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.