Tool life simulation by finite element method (FEM) in hard machining of AISI D2 harden steel
Manufacturing industry in this decade witnesses the emerging of many machining technologies that have been growing rapidly. One of the challenging reservations is machining of hard metals. The hard metal materials are widely used in the engineering space, armaments, tool and die, mining, and manufac...
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| Format: | Thesis |
| Published: |
2015
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| Subjects: | |
| Online Access: | http://eprints.uthm.edu.my/7500/ http://eprints.uthm.edu.my/7500/1/azizun_nusdin_azizi.pdf |
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| Summary: | Manufacturing industry in this decade witnesses the emerging of many machining
technologies that have been growing rapidly. One of the challenging reservations is
machining of hard metals. The hard metal materials are widely used in the
engineering space, armaments, tool and die, mining, and manufacturing. Normally,
the hard metal cutting materials (> 45 HRC) is operated by using a grinding machine
or electrical machining (EDM). This study is carried out to reduce the costs, to obtain
short cycle time, low processing steps, high flexibility and to produce of the smooth
surface metals. Most of the hard metals cutting had experienced a difficulty to
optimise the cutting condition with regard to the cost, time and accuracy of work.
Therefore, this research has been directed towards in investigating the tool life of
TiAlN Sandvik PVD coated carbide that use in cutting of hardened steel, AISI D2
(58-62 HRC). In this study, the pyhsical phenomenon of AISI D2 machining was
studied using numerical simulations through the 3D Finite Element Method (FEM)
and it was accomplished by DEFORM 3D software. The main criteria analyzed were
temperature, cutting force, stress and strain. The simulation results obtained were
used to explain the effects of machining parameters on the tool life results that
derived by the previous researchers through the experiment. In the experimental
works, the machining process was carried out using CNC vertical milling machine in
dry condition. The cutting parameters selected were in the range of 80-120 rpm,
stepover 3-5mm and depth of cut was kept constant at 0.5 mrn. Findings show that
the distribution of temperature, stress, strain and force were inversely proportional to
the tool life that experimentally obtained. Finally, the highest acceptable value of
tool life was given by the lowest cutting speed of 80 RPM. It was found that the
results from DEFORM 3D FEM simulations are able to fairly explain and validate
the experimental results obtained by the previous researchers. |
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