Physics-Based Simulations of Chip Flow over Micro-Textured Cutting Tool in Orthogonal Cutting of Alloy Steel
Physics-based process simulations have the potential to allow virtual process design and the development of digital twins for smart machining applications. This paper presents 3D cutting simulations using the finite element method (FEM) and investigates the physical state variables that are fundamen...
| Main Authors: | , , |
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| Format: | Article |
| Language: | English |
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MDPI AG
2021-06-01
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| Series: | Journal of Manufacturing and Materials Processing |
| Subjects: | |
| Online Access: | https://www.mdpi.com/2504-4494/5/3/65 |
| _version_ | 1797529298960121856 |
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| author | Kaushalendra V. Patel Krzysztof Jarosz Tuğrul Özel |
| author_facet | Kaushalendra V. Patel Krzysztof Jarosz Tuğrul Özel |
| author_sort | Kaushalendra V. Patel |
| collection | DOAJ |
| description | Physics-based process simulations have the potential to allow virtual process design and the development of digital twins for smart machining applications. This paper presents 3D cutting simulations using the finite element method (FEM) and investigates the physical state variables that are fundamental to the reduction in cutting forces, friction, and tool wear when micro-textured cutting tools are employed. For this goal, textured cemented carbide cutting tool inserts are designed, fabricated, and tested in the orthogonal dry cutting of a nickel-chromium-molybdenum alloy steel. Cutting forces and friction coefficients are compared against the non-textured tool, revealing the effects of texture parameters. Chip flow over the textured tool surface and process variables at the chip-tool contact are investigated and compared. The results reveal the fundamental sources of such improvements. Archard’s wear rate as a composition of process variables is utilized to compare experimental and simulated wear on the textured cutting tools. The effects of texture and cutting conditions on tool wear and adhesion characteristics are further discussed on the simulation results with experimental comparisons. It was found that the results obtained from these simulations provide further fundamental insights about the micro-textured cutting tools. |
| first_indexed | 2024-03-10T10:11:50Z |
| format | Article |
| id | doaj.art-8e45b03f7d174e3588b1b71a8817b9b4 |
| institution | Directory Open Access Journal |
| issn | 2504-4494 |
| language | English |
| last_indexed | 2024-03-10T10:11:50Z |
| publishDate | 2021-06-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Journal of Manufacturing and Materials Processing |
| spelling | doaj.art-8e45b03f7d174e3588b1b71a8817b9b42023-11-22T01:07:48ZengMDPI AGJournal of Manufacturing and Materials Processing2504-44942021-06-01536510.3390/jmmp5030065Physics-Based Simulations of Chip Flow over Micro-Textured Cutting Tool in Orthogonal Cutting of Alloy SteelKaushalendra V. Patel0Krzysztof Jarosz1Tuğrul Özel2Manufacturing and Automation Research Lab., Department of Industrial and Systems Engineering, Rutgers University-New Brunswick, Piscataway, NJ 08854, USAManufacturing and Automation Research Lab., Department of Industrial and Systems Engineering, Rutgers University-New Brunswick, Piscataway, NJ 08854, USAManufacturing and Automation Research Lab., Department of Industrial and Systems Engineering, Rutgers University-New Brunswick, Piscataway, NJ 08854, USAPhysics-based process simulations have the potential to allow virtual process design and the development of digital twins for smart machining applications. This paper presents 3D cutting simulations using the finite element method (FEM) and investigates the physical state variables that are fundamental to the reduction in cutting forces, friction, and tool wear when micro-textured cutting tools are employed. For this goal, textured cemented carbide cutting tool inserts are designed, fabricated, and tested in the orthogonal dry cutting of a nickel-chromium-molybdenum alloy steel. Cutting forces and friction coefficients are compared against the non-textured tool, revealing the effects of texture parameters. Chip flow over the textured tool surface and process variables at the chip-tool contact are investigated and compared. The results reveal the fundamental sources of such improvements. Archard’s wear rate as a composition of process variables is utilized to compare experimental and simulated wear on the textured cutting tools. The effects of texture and cutting conditions on tool wear and adhesion characteristics are further discussed on the simulation results with experimental comparisons. It was found that the results obtained from these simulations provide further fundamental insights about the micro-textured cutting tools.https://www.mdpi.com/2504-4494/5/3/65cuttingmicro-texturechip flowfinite element method |
| spellingShingle | Kaushalendra V. Patel Krzysztof Jarosz Tuğrul Özel Physics-Based Simulations of Chip Flow over Micro-Textured Cutting Tool in Orthogonal Cutting of Alloy Steel Journal of Manufacturing and Materials Processing cutting micro-texture chip flow finite element method |
| title | Physics-Based Simulations of Chip Flow over Micro-Textured Cutting Tool in Orthogonal Cutting of Alloy Steel |
| title_full | Physics-Based Simulations of Chip Flow over Micro-Textured Cutting Tool in Orthogonal Cutting of Alloy Steel |
| title_fullStr | Physics-Based Simulations of Chip Flow over Micro-Textured Cutting Tool in Orthogonal Cutting of Alloy Steel |
| title_full_unstemmed | Physics-Based Simulations of Chip Flow over Micro-Textured Cutting Tool in Orthogonal Cutting of Alloy Steel |
| title_short | Physics-Based Simulations of Chip Flow over Micro-Textured Cutting Tool in Orthogonal Cutting of Alloy Steel |
| title_sort | physics based simulations of chip flow over micro textured cutting tool in orthogonal cutting of alloy steel |
| topic | cutting micro-texture chip flow finite element method |
| url | https://www.mdpi.com/2504-4494/5/3/65 |
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