FEM based simulation and analysis of stainless steel turning

Abstract

In this paper, an attempt has been made to study the effect of cutting speed and feed rate on the cutting forces and chip breakage in turning process. Nowadays researches on metal cutting processes are being done in different laboratories as it is of importance not only for understanding the fundamentals of metal cutting processes but also for the design of different metals used in laboratories both for scientific and engineering purpose. Understanding of the fundamentals of metal cutting processes through the experimental studies has some limitations. Metal cutting modeling provides an alternative way for better understanding of machining processes under different cutting conditions. Using the capabilities of finite element models, it has recently become possible to deal with complicated conditions in metal cutting. Finite element modeling makes it possible to model several factors that are present during the chip formation .As simulation tool for the purpose of this study; the FEM software used is AdvantEdge FEM. AdvantEdge FEM is a CAE (Computer Aided Engineering) software solution for the optimization of metal cutting. This modeling software is used by those looking to improve tool design, increase material removal rates, extend tool life, improve part quality, and much more. We use AdvantEdge FEM to decrease the need for trial and error testing. The simulation results on cutting forces and chip thicknesses are compared with experimental data in order to indicate the consistency and accuracy of the results when conducting the comparison. Actually this paper presents the advantage of using software for simulation of cutting process and study of stainless steel turning. To complete our research wok we use 2D Finite Element Model (F.E.M.) of chip formation process, proposed in the software named AdvantEdge FEM with an experimental set up in the laboratory. The experimental validation showed a good qualitative agreement. Thus, FEM of cutting process can be considered as a promising and reliable tool for machining development within the near future.