Analysis of Hard Turning Process of AISI D3-Thermal Aspects

Authors: B. Varaprasad, C. Srinivasa Rao

Abstract:

In the manufacturing sector, hard turning has emerged as vital machining process for cutting hardened steels. Besides many advantages of hard turning operation, one has to implement to achieve close tolerances in terms of surface finish, high product quality, reduced machining time, low operating cost and environmentally friendly characteristics. In the present study, three-dimensional CAE (Computer Aided Engineering) based simulation of  hard turning by using commercial software DEFORM 3D has been compared to experimental results of  stresses, temperatures and tool forces in machining of AISI D3 steel using mixed Ceramic inserts (CC6050). In the present analysis, orthogonal cutting models are proposed, considering several processing parameters such as cutting speed, feed, and depth of cut. An exhaustive friction modeling at the tool-work interfaces is carried out. Work material flow around the cutting edge is carefully modeled with adaptive re-meshing simulation capability. In process simulations, feed rate and cutting speed are constant (i.e.,. 0.075 mm/rev and 155 m/min), and analysis is focused on stresses, forces, and temperatures during machining. Close agreement is observed between CAE simulation and experimental values.

Keywords: Hard-turning, computer-aided engineering, computational machining, finite element method.

Digital Object Identifier (DOI): doi.org/10.5281/zenodo.1126501

References:

[1] Byrne, G., Dornfeld, D., Denkena, B., 2003. Advanced cutting technology. Annals of the CIRP 52 (2), 483–507.
[2] Klocke, F., Brinksmeier, E., Weinert, K., 2005. Capability profile of hard cutting and grinding processes. Annals of the CIRP 54 (2), 557–580.
[3] Klocke, F., Kratz, H., 2005. Advanced tool edge geometry for high precision hard turning. Annals of the CIRP 54 (1), 47–50.
[4] Denkena, B., Becker, J.C., de Leon-Garcia, L., 2005. Study of the influence of the cutting edge microgeometry on the cutting forces and wear behavior in turning operations. In: Proceedings of the 8th CIRP, International Workshop on Modelling of Machining Operations, Chemnitz, Germany, pp. 503–507.
[5] Özel, T., Hsu, T.-K., Zeren, E., 2005. Effects of cutting edge geometry, workpiece hardness, feed rate and cutting speed on surface roughness and forces in finish turning of hardened AISI H13 steel. International Journal of AdvancedManufacturing Technology 25, 262–269.
[6] Zou B., Chen M., and Li S., 2011, “Study on finish-turning of NiCr20TiAl nickel-based alloy using Al2O3/TiNcoated carbide tools”. International Journal of Advanced Manufacturing Technology, Vol.53, p.81–92.
[7] Fahad M., Mativenga PT., and Sheikh MA., 2012, “A comparative study of multilayer and functionally graded coated tools in high-speed machining”, International Journal of Advanced Manufacturing Technology, Vol. 62, p. 43–57.
[8] Gopalsamy BM., Mondal B., and Ghosh S., 2009, “Optimisation of machining parameters for hard machining: grey relational theory approach and ANOVA”. International Journal of Advanced Manufacturing Technology, Vol.45, p.1068-1086.
[9] Ahilan C., Kumanan S., and Sivakumaran N., 2010, “Application of Grey based Taguchi method in multi response optimization of turning process”. Advances in Production Engineering & Management, Vol. 5(3), p. 171- 180.
[10] Özel, T., 2003. Modeling of hard part machining: effect of insert edge preparation for CBN cutting tools. Journal of Materials Processing Technology 141, 284– 293.
[11] Yen, Y.C., Jain, A., Altan, T., 2004. A finite element analysis of orthogonal machining using different tool edge geometry. Journal of Materials Processing Technology 146, 72–81.
[12] Hua, J., Shivpuri, R., Cheng, X., Bedekar, V., Matsumoto, Y. Hashimoto, F., Watkins, T.R., 2005. Effect of feed rate,workpiece hardness and cutting edge on subsurface residual stress in hard turning of bearing steel using chamfer and hone edge geometry. Materials Science and Engineering A394, 238–248.
[13] Chen, L., ElWardany, T.I., Nasr, M., Elbestawi, M.A., 2006. Effects of edge preparation and feed when hard turning a hotwork die steel with polycrystalline cubic boron nitride tools. Annals of the CIRP 55 (1), 88–92.
[14] Umbrello, D., Rizzuti, S., Outeiro, J.C., Shivpuri, R., M’Saoubi, R., 2008. Hardnessbased flowstress for numerical simulation of hardmachining AISI H13 tool steel. Journal of Materials Processing Technology 199 (1–3), 64–73.
[15] Karpat, Y., Özel, T., 2008a. Mechanics of high speed machining with curvilinear tools. International Journal of Machine Tools and Manufacture 49, 195–208.
[16] Ceretti, E., Lazzaroni, C., Menegardo, L., Altan, T., 2000. Turning simulations using a three-dimensional FEM code. Journal of Materials Processing Technology 98,99–103.
[17] Guo, Y., Liu, C.R., 2002. 3D FEA modeling of hard turning. ASME Journal of Manufacturing Science and Engineering 124, 189–199.
[18] Aurich, J.C., Bil, H., 2006. 3D finite element modelling of segmented chip formation. Annals of the CIRP 55 (1), 47–50.
[19] Rosochowska, M., Balendra, R., Chodnikiewicz, K., 2003. Measurements of thermal conductance. Journal of Materials Processing Technology 135, 204–210.
[20] Incropera. F.P., and DeWitt, D.P.,2001, Fundamentals of Heat and MassTra, Willey, Newyork.
[21] G.R. Johnson and W.H. Cook, Engineering Fracture Mechanics, 21(1985), 31.