FE Simulation of Turning Metal Cutting With Multi-coated Tools

Abstract

The metal cutting process is an integral part of today's industry. However, understanding the basic principles of the metal cutting processes through experiments has its limitations. On the other hand, FE modelling can provide researchers an unconventional way to better study the machining processes under different cutting conditions as it can calculate many complicated conditions at once such as metal temperature, chip tool interface, tool wear, etc. The aim of this research is to develop innovative methods to produce high grade products and decreasing the manufacturing time and cost at the same time. Chip formation is still one of the more problematical parts in the field of machining that still requires numerous research. A number of different prediction models have been proposed over the years. The Johnson-Cook damage model was chosen to be the main focus for this research. The approach used in this research was to obtain the experimental data of the cutting process of Ti-6Al-4V alloy using the tungsten carbide (WC) tool. Then use FEM software to simulate the process with the exact conditions and then compare the results of both studies to propose a solution for any inaccuracy or inconsistency that may arise. The FEM software used for this study is DEFORM-3D. It is a very unique simulation software that implements the Finite Elements Methods to model composite machining processes (cutting, turning, drilling etc.) in both 2D and 3D. The specific results were taken for the cutting forces and chip formation from the simulation and were compared with the experimental results for its accuracy.