DOI Number : 10.5614/itbj.eng.sci.2010.42.2.6
Hits : 0

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

Hendri Yanda1, Jaharah A. Ghani2 & Che Hassan Che Haron3

1Department of Mechanical Engineering, Faculty of Engineering, Andalas University
2,3Department of Mechanical and Materials Engineering, Faculty of Engineering  and Built Environment, Universiti  Kebangsaan Malaysia
 Email : hendri.yanda@ft.unand.ac.id


Abstract.

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.



Keywords: cutting force; Deform-3D; effective stress; finite element method; orthogonal cutting; rake angle; total Von Misses strain.

Download Article
 
Bahasa Indonesia | English
 
 
 

Notification:

Begin on 10 October 2014 this website is no longer activated for article process in Journal of Mathematical and Fundamental Sciences, Journal of Engineering and Technological Sciences, Journal of ICT Research and Applications and Journal of Visual Art and Design. The next process will be proceeded under new website at http://journals.itb.ac.id.

For detail information please contact us to: journal@lppm.itb.ac.id.

 
       
       
       ITB Journal Visitor Number #15941475       
       Jl. Tamansari 64, Bandung 40116, Indonesia Visitor IP Address #       
       Tel : +62-22-250 1759 ext. 121 2011 Institut Teknologi Bandung       
       Fax : +62-22-250 4010, +62-22-251 1215 XHTML + CSS + RSS       
       E-mail : journal@lppm.itb.ac.id or proceedings@lppm.itb.ac.id Developed by AVE