PRESENTATION ON PROJECT TITLED

FEM study on the effect of the tool geometry on the machining aspects
(Turning) of steel alloy
Under the supervision of,
Dr.G.SRINIVASU,
Assistant professor,
Mechanical Engineering,

presented by,
D.ARAVIND REDDY-12119018
DUKKA DINESH-12119024
N.V.CHAITANYA MANOHAR-12119047
P.MANOJ KUMAR REDDY-12119057

INTRODUCTION

THE TURNING PROCESS

Turning is a very important machining process in which a singlepoint cutting tool removes material from the surface of a rotating
cylindrical work piece.
The cutting tool is feed linearly in a direction parallel to the axis of
rotation.
Therefore, Five cutting parameters, i.e. cutting speed, feed rate, and
depth of cut, tool geometry (nose radius) and cutting condition
exist.
The free body diagram of the turning process with different forces
is below, called Merchants force diagram.

Figure-1
(Turning process)
diagram)

Figure-2
(Merchant circle

Finite Element Analysis of Turning Process

Finite element analysis is a most useful and accurate approach
for the determination of field variables that is made possible by
advancements in computational and processing power of
computers
In this method of analysis, a complex region defining a
continuum is discredited into simple geometric shapes called
finite elements.
The Present work is also based on the application of finite
element for analysis of different parameters while using single
point cutting tool for turning operation.

 Modelling 3D cutting process using finite element techniques is

an area of on going research activity due to significant cost
savings and offers insights into the process which are not easily
measured in experiments.

ABOUT DEFORM 3D
DEFORM is a Finite Element Method (FEM) based process
simulation system designed to analyse various forming and heat
treatment processes used by metal forming and related industries.
Unlike general purpose FEM codes, DEFORM is tailored for
deformation modelling.

 Cutting forces, cutting temperatures, chip shape, tool wear and

tool life computations can be performed using this system.
The insert geometry can be made available in STL form,
generated from any CAD system.

LITERATURE REVIEW

 In a study by Tugrul O zel , Taylan Altan[1], they

determined work piece flow stress and friction at
the chiptool contact for high-speed cutting by
using analytical methods and compared them
with the experimental or measured values.
They also used DEFORM 2D in the process to initially
compare the estimated force values with the values obtained by
performing simulations using DEFORM 2D .
The results obtained are satisfactory , but they can not improve
the conditions for optimum cutting.
The graphs obtained by them are shown below

The graphs obtained by them are shown below:

 In another study by D. Ulutan, I. Lazoglu and C. Dinc ,[2]

they predicted three-dimensional temperature in machining
processes using finite difference method.
They used many formulae to determine the convective and
conduction coefficients for the heat transfer between the chip
and tool.

 They used expensive experimental setup comprising of

INFRARED equipment to determine experimental temperature
condition at the interface.

 The results obtained by analytical methods are compared with

the ones obtained by experimental methods .As far the below
graphs are considered, the values are agreeable.

 In another study by Tugrul O zel ,[3] the influence of friction

models on finite element simulations of machining is studied.
Almost same as the above cases, they also used analytical
formulae to calculate the force and the stress rates.
Those values are then compared with the values those obtained
with FEM simulations.
Variable friction model is used to predict the values throought
the study.

Some of the results obtained by them are below :-

PROBLEM
IDENTIFICATION

 Since the metal turning operations have a very complex

structure, it is quite difficult to solve them analytically.
Experimental method is both costly and time-consuming.
However, this complex structure can be solved easily by using
numeric analyses based on finite element method (FEM).
Modelling metal turning processes in three dimensional (3D)
by using FEM may be useful for validation of experimental
studies and it can be also considered as a reliable tool for new
metal removal techniques.

 The PROBLEM of suboptimum conditions which lead to

decrease in efficiency of the machining operation can be solved
by considering above methods.
Another PROBLEM for machining is the cost of machining for
costly materials and for which machining cost is very high .For
example Titanium is difficult to machine .But this can be easily
done by using software.
By using this method, improvements in the output conditions
can also be made by changing input variables and conditions.

 Various simulations can be done for each experiment and

optimum condition at which minimum tool wear and minimum
temperature occurs can be found.
By changing the tool definition temperature at the tool work
piece interface can be reduced.
Here if a tool with small grooves cut on it is used, it would be
able to cut the work piece effectively. The grooves can be made
by using diamond cutting tool.

 As diamond cutting of a tool would be costly and that too

making micro grooves within ultra-precision is even more
costly, we can simply use the software simulation by designing
the tool in the 3d drawing methods .
The required STL file can be made by using AUTOCAD.

METHODOLOGY

STARTING WITH 3D MACHINING

PROCESS SETUP AND

CONDITIONS

INSERT TOOL DEFINITION

TOOL HOLDER DEFINITION

TOOL MESH GENERATION

WORK PIECE GEOMETRY

LOAD WORK PIECE

MATERIAL

SIMULATION CONTROLE AND

TOOL WEAR DEFINITION

RUNNING THE SIMULATION

EXPECTED
OUTCOME

Development of FEM model to study the effect of

tool modification on :
Interface temperature
Material removal rate
Tool wear
Cutting forces

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