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Finite element simulation of cutting process under the worn tool edge geometries

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Abstract

Finite element (FE) technique has been used extensively to have a deeper understanding on the mechanics of metal cutting and for process optimization. The accuracy of the model is dependent on both the highly non-linear material plasticity model and the simulated friction condition between contacting surfaces. Hence, majority of the predicted results were validated from direct or indirect experimental results. Measurement of cutting forces magnitude and temperature field are direct techniques to validate the model. Indirect methods are chip morphology and residual stresses measurement from the newly generated surface. In this paper, a unique indirect method is proposed to validate the accuracy of the FE model. This method predicts the tool wear rate by using the average contact pressure and interface temperature acquired from finite element simulation, as the inputs for the Usui’s tool wear rate equation. Orthogonal cutting experiments were performed in specific ranges of cutting speed and feed rate. The workpiece material used was AISI 1045 at 86 HRB, and tool material was uncoated carbide. Tool cutting edge geometry was analyzed in different steps of the cutting process, and worn edge geometries were obtained. The worn edge geometries were then used to build the FE cutting models. Based on the simulation results when the flank wear length increases, the temperature field prediction showed that the region of maximum temperature shifted from the rake face to the flank face region. The contact pressure increased substantially with cutting speed rather than feed rate. The predicted wear rate agreed well with experimental results. Using tool wear rate to predict the accuracy of the FE cutting model is limited to the orientation of the rake and flank face surfaces.

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Acknowledgments

The authors would like to thank the Mechanical Engineering Department at McMaster University and McMaster Manufacturing Research Institute (MMRI) for providing the laboratory infrastructure.

Data availability and material availability

All the data and material in this paper are original and available upon request.

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Funding

This work was funded by Natural Sciences and Engineering Research Council of Canada (NSERC) through the Canadian Network for Research and Innovation in Machining Technology (CANRIMT) and Discovery Grant programs.

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Authors and Affiliations

  1. Department of Mechanical Engineering, McMaster University, 1280 Main St. W., Hamilton, Ontario, L8S 4L7, Canada

    Keyvan Hosseinkhani & Eu-gene Ng

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  1. Keyvan Hosseinkhani
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  2. Eu-gene Ng
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Contributions

Conceptualization, methodology, experiment, finite element simulation, and data analysis by Keyvan Hosseinkhani. Resources and funding acquisition by Eu-gene Ng. Writing—original manuscript draft preparation by Keyvan Hosseinkhani. Writing—review and editing by Eu-gene Ng. Project administration by Keyvan Hosseinkhani and Eu-gene Ng.

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Correspondence to Keyvan Hosseinkhani.

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We would like the manuscript entitled “Finite element simulation of cutting process under the Worn Tool Edge Geometries” by Keyvan Hosseinkhani and Eu-gene Ng to be considered for publication in the International Journal of Advanced Manufacturing Technology.

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Hosseinkhani, K., Ng, Eg. Finite element simulation of cutting process under the worn tool edge geometries. Int J Adv Manuf Technol 116, 3991–4006 (2021). https://doi.org/10.1007/s00170-021-07725-9

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