Investigating Tool Wear, Chip Behaviour and Spring Back Action Using FEM

Abstract

The tool wear found in machining processes represents main obstacle for machinability due to its detrimental effects on surface roughness, material removal rate and machining economy. A nonlinear thermomechanical finite element model was developed to simulate the tool chip interaction. This model predicts not only the chip morphology and chip flow direction, cutting forces values, stress distribution, but also can use to predict tool wear. Furthermore, the effect of elastic deformation (spring back) and the thermal effect have been considered in the model. Cutting force was predicted and compared with the conducted experimental work. Dry turning operation was carried out on low carbon steel using carbide tool. The tool/workpiece interface stress on flank face was calculated and compared with the FEM. Predicted results show good correlation with the FEM. FE model was verified experimentally by measuring the cutting force. The friction on the flank face and spring back concentrates the stress on the flank face.