Materials

& Design
Materials and Design 26 (2005) 549554
www.elsevier.com/locate/matdes

Short Communication

Finite element analysis of bending occurring while

cutting with high speed steel lathe cutting tools
Abdullah Duran *, Muammer Nalbant
Gazi University, Mechanical Engineering Department, Technical Education Faculty, Besevler, Ankara 06500, TeknikokuIIar, Turkey
Received 4 February 2004; accepted 26 July 2004
Available online 6 October 2004

Abstract
The bending which occurs on a cutting tool during machining on a lathe aects tool life, surface roughness and dimension correctness. In this research, the bending which has been calculated by Castigliano theorem has been compared with the bending
obtained by nite element method. Under the constant cutting conditions, material C
1060 has been machined with high speed steel
(HSS) lathe cutting tools having 60
, 75
and 90
of cutting edge angle. It was determined by using ANSYS nite elements program
that the bending of the cutting tool generated by the forces, which varied between 1360 N and 1325 N and occurred during cutting,
varied between 0.039958 and 0.04373 mm. According to the results, it has been observed that the bending that was calculated by
Castigliano theorem and that varied between 0.03542 and 0.034505 mm was almost the same with the bending determined by nite
elements method. In other words, it was seen that the calculated values approach to the analysed results up to 0.4% .
 2004 Elsevier Ltd. All rights reserved.
Keywords: Finite elements method; Bending; Cutting forces

1. Introduction
Various machine tools and cutting tools are used in
metal cutting. Cutting tools for turning can generally
be divided into two groups: high speed steels and cemented carbides. High speed steel (HSS) cutting tools can be
subdivided into three groups according to their manufacture: single, brazed and indexable inserts [1,2].
Cutting tool geometry, chip geometry, cutting speed,
cutting tool and workpiece material, cutting speed and
cutting uid are the main factors aecting the metal cutting process [3,4].
Tool geometry, one of the most important factor
aecting metal cutting process, is determined by rake angle, side clearance angle, side cutting edge angle and
back rake angle. Tool geometry is an important factor

Corresponding author.
E-mail address: aduran@gazi.edu.tr (A. Duran).

0261-3069/$ - see front matter  2004 Elsevier Ltd. All rights reserved.
doi:10.1016/j.matdes.2004.07.028

having inuence on cutting forces and tool life. For an

optimum turning operation, correct selection of cutting
parameters as well as the length of tool holder extending
from its post are essential [5]. That is because, incorrect
selection of cutting parameters leads to rapid tool wear,
breakage and plastic deformation. This increases machine tool idle time due to the changing of damaged cutting tools and causes some other problems such as poor
surface quality and wrong workpiece dimensions. This,
in turn, increases the overall cost [6].
Determination of cutting parameters through conventional methods is mostly not possible. Therefore,
the use of high capacity computers is also gaining
importance as it is possible to nd appropriate solutions
for metal cutting operation. Approximate solution
methods giving very close results to those obtained by
the experimental work are appealing as they are easy
to use and there is no necessity to carry out costly experimental work [7]. Parallel to the development in the
computer technology, nite element analysis (FEM)

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A. Duran, M. Nalbant / Materials and Design 26 (2005) 549554

method, one of the approximate solution methods, has

been increasingly used. Finite element method gives very
close results to the real values and, therefore, it is now a
well accepted numerical method [811].
In this study, deection of HSS cutting tool during
turning was investigated using ANSYS version 5.4 program based on the tool length extending through the
tool post. The deection of the tool was also calculated
using Castigliano theory and the results were compared
to those obtained using ANSYS program.
Fig. 2. Cutting forces acting on the cutting tool during turing.

2. Basics of the metal cutting

2.1. Cutting process
Metal cutting is a complex physical phenomenon
which involves elastic and plastic deformation, intense
friction and heat, chip formation and cutting tool wear.
In order to eect cutting action, the cutting tool (as
shown in Fig. 1(a)) is forced against the workpiece and
is moved relative to the workpiece. As the result, the
workpiece is initially deformed elastically (Fig. 1(b))
and when the workpieces yield strength is exceeded
plastic deformation occurs. Plastic deformation leads
to chip formation (Fig. 1(c)). The formed chip leaves
the workpiece through the cutting tool rake face. The
ow of the chip occurs in various ways depending on
the workpiece properties and cutting conditions [5].
2.2. Cutting forces
The necessary chip formation force required to overcome the developed stresses during chip formation process can be divided into three components: cutting force
(Fz), feed force (Fs) and radial force (Fp). Cutting forces
developed during turning are depicted in Fig. 2 [13].

Cutting force (Fs) acts against the workpiece turning

motion and forces the cutting tool downwards perpendicular to the workpiece axis. Feed force (Fv) acts parallel to the workpiece turning axis and is in the reverse
direction of the feed. Radial force (Fp) acts perpendicularly to the machined surface and forces the cutting tool
backwards.
If a cutting tool xed on the tool post is considered a
cantilever beam as shown in Fig. 3, the deection of the
tool (dB) due to Fs force should be ideally zero during
cutting. However, this is not possible in real cutting conditions and a deection value of <0.1 mm is permitted
for rough machining operations [14].
2.3. Castigliano theory
According to Castigliano theory, partial derivation of
the total internal stress energy with respect to the one of
the applied external forces gives the displacement of the
point of applied force in its application direction [15].
The displacement of the equal cross-sectioned beam at
point B (Fig. 4(a)) under Fs force can be found using
Castigliano theory.

Fig. 1. Chip formation process [3,12].

A. Duran, M. Nalbant / Materials and Design 26 (2005) 549554

551

fore, called nite element method [10]. The main idea in

nite element method is to solve a complex problem by
replacing it with a simple problem. By using the existing
mathematical methods, in practice real or approximate
solutions cannot be found for many problems. However,
nite element method can be used to nd approximate
solutions for these problems. In nite element method,
the solution zone is composed of adjacent sub parts
which are called nite element. It can be assumed that
these sub parts are held together by nuts and screws.
It is also assumed that when the bonding is removed,
the sub parts are separated.

3. Materials and methods

Fig. 3. Representation of the cutting tool as a cantilever beam.

The bending moment at any point of the beam in Fig.

4(b) can be found using the following equation:
M xF s :

If the M moment changes along the beam, internal stress

energy developed as the result of basic bending moment
in the beam then dx length element strain energy is
found using

3.1. The materials used for the tests and the cutting forces
A HSS cutting tool of 12 12 100 mm in dimensions was used as shown in Fig. 5. This tool was xed
on the tool post of a dynamometer capable of measuring
cutting forces between 5 and 300 N. The tool was
ground to give the following angles:
Rake angle cn 12

Side relief angle a 6

M 2 dx
:
2
2EI
The total strain energy is calculated in the following
way:
Z L
M2
u
dx:
3
X 0 2EI
du

The bending in the beam (dB) can be found by rearranging Eq. (2) in the following form:

L
Z L
oy t
2xF s x
F s x3


F sL
dx
4

dB

3EI :
oF s
2EI
EI
3
x0
0
2.4. Finite elements
In nite elements method, it is assumed that a part is
divided into so many small parts. This method is, there-

Fig. 5. Octagonal ring dynamometer capable of measuring three

cutting force components [12].

Fig. 4. Single side cantilever beam.

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A. Duran, M. Nalbant / Materials and Design 26 (2005) 549554

End relief angle ai 6

Included angle e 87

In this study, cutting tests were performed using three
dierent side cutting edge angles: 60
, 75
and 90
.
C
1060 steel was selected as the workpiece material
with a tensile strength of 700 N/mm2. The length of
the cutting tool extending from the tool post was 30 mm.
The analysis of deection occuring during turning
using a HSS cutting tool (B 12 100 TS 95/1 HSS-Co)
12 12 100 mm in dimensions was analysed using nite element method. The cutting force values required
for the analysis were recorded during turning of C

1030 steel at a cutting speed of 30 m/min, depth of cut

of 2 mm and feed rate of 0.2 mm/rev by using three different side cutting edge angles (60
, 75
and 90
). The
turning tests were carried out without coolant and the
cutting forces were measured using the dynamometer
shown in Fig. 5.
3.2. Division of the solution zone into the nite elements
and the stress analysis
Modulus of elasticity = 2 105 N/mm2;
Poisson ratio (l) = 0.3;
Tensile strength = 850 N/mm2;
Density = 78.33 N/dm3.
The cutting tool was modelled using Pro/ENGINEER version 16.0 as a solid model and the deection
of cutting tool under the cutting forces was analysed
using ANSYS version 5.4 nite element analysis program. Having created the solid model of the cutting
tool, this model was imported into ANSYS and divided

Fig. 6. Application of the forces to the cutting edge angle tool.

into the nite elements. After this stage, boundary conditions were applied. As was mentioned earlier on, the
cutting tool was like a cantilever beam with 30 mm
length. Cutting forces were applied through the cutting
edge as a uniform loads in x, y and z directions as shown
in Fig. 6. The cutting tool was regarded as having isotropic properties and some of them required for the
solution were entered to the program through isotropic
material properties icon. In order to calculate the total
stress of the dened component, global stiness matrix
becomes 3n lines and 3n columns as the component
was 3 freedom level.
After this stage, Fig. 7, showing the amount of deection of the each point of the cutting tool, was obtained.
As can be seen from this gure, nine dierent colours
were obtained on the cutting tool having 60
side cutting
edge angle. These colours show the amounts of deections or in other words they show clearly the deections
in decreasing order from the cutting tool edge towards
the back. As can be seen from the gure, the maximum

Fig. 7. Deection values of 60
side cutting edge angle tool.

A. Duran, M. Nalbant / Materials and Design 26 (2005) 549554

553

Fig. 8. Deection values of 75
side cutting edge angle tool.

Fig. 9. Deection values of 90
side cutting edge angle tool.

deection was observed at the tool tip, 0.04373 mm.

Similarly, Fig. 8 shows the deection of 75
side cutting
edge angle tool, while Fig. 9 shows that of 90
side cutting edge angle tool.

4. Measurement results
C
1060 steel workpiece was held between the chuck
and tailstock without run-out. Cutting force measure-

ment system was set up and it was set to the conditions

(the same gain, feeding voltage and number of data
read) prevailing during the system calibration. Then,
the system was run idle for 30 min so that steady state
was reached before taking the readings. For each position of the cutting tool given in Section 3.1, cutting tests
were performed at constant cutting speed, feed rate and
depth of for 5 s. The strain values corresponding to the
Fs, Fv and Fp values were recorded on a computer during
the cutting [5]. This practice was performed for each of

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A. Duran, M. Nalbant / Materials and Design 26 (2005) 549554

Table 1
The measured cutting forces [13]
Side cutting edge angle

60

75

90

The mean forces measured by the

dynamometer (N)
(Fs)

(Fv)

(Fp)

136
1330
1325

540
530
525

270
265
265

Table 2
Deection of the cutting tool
Side cutting
edge angle

Deection values
obtained by
ANSYS (mm)

Deection values
obtained by
Castigliona
method (mm)

Dierence
(% deviation)

60

75

90

0.04373
0.04065
0.03995

0.03542
0.0344
0.0345

8
6
4

90
, 75
and 60
side cutting edge angles, respectively.

Therefore, it can be said that ANSYS program and Castigliano theory produced almost the same values. The
least deviation between the results obtained by ANSYS
and Castigliano theory for the tool having 90
side cutting edge angle can be explained by the cutting tool
cross-sections used in the both methods which were
the most similar for this cutting tool.
The resulting deviations do not only stem from the
cutting tool cutting angles. That is because the application of forces to the cutting tool are dierent. That is, in
the computer based method all the three force components are applied uniformly along the cutting edge as
in real cutting operation, while in Castigliano theory
only Fs force is applied at the cutting edge as the point
load.
However, all the results show that Castigliano theory
used for calculations of the deections of square and
rectangular cross-sectioned cantilever beam can also be
used to determine the deections of single part HSS
tools having 90
, 75
and 60
side cutting edge angles.

References

Fig. 10. Cutting tool side cutting edge angles.

the side cutting edge angle. The resulting cutting forces

are given in Table 1. The highest analysis values of
deections of the cutting tools having 60
, 75
and 90

side cutting edge angles found by nite element method
are compared to theoretically obtained ones through
Castigliano method explained in Section 2.2, Table 2.
As shown in Table 2, the least deviation was observed
for the 90
side cutting edge angle tool. That is because
this cutting tool had less changes in its cross-sectional
area than 60
and 75
side cutting edge angle tools
depending on side cutting edge angle. This is shown in
Fig. 10 schematically. In addition, in calculations with
Castigliano theory Fs was applied as a point load at
the cutting edge of the cutting tool, while in ANSYS
program all the cutting force components Fs, Fp and
Fv forces occurring during real cutting operations were
applied as uniformly distributed load along the cutting
surface as stated in Fig. 6.

5. Conclusions
The dierences between the cutting tool deection
values obtained by ANSYS program and Castigliano
theory were approached by 0.4%, 0,6% and 0.8% for

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