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

Abstract

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