Optimization of tool geometry design for free cutting steel (AISI 12L14) in turning operation
The need for major improvements in the design of cutting tools are due to the demands of delivering high dimensional accuracy and low surface roughness products in turning operation. An optimization of cemented carbide (WC) tool geometry design for AISI 12L14 free cutting steel in turning proc...
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| Main Author: | |
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| Format: | Thesis |
| Language: | English |
| Published: |
2017
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| Subjects: | |
| Online Access: | http://psasir.upm.edu.my/id/eprint/71454/1/FK%202018%20105%20IR.pdf |
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| Summary: | The need for major improvements in the design of cutting tools are due to the
demands of delivering high dimensional accuracy and low surface roughness
products in turning operation. An optimization of cemented carbide (WC) tool
geometry design for AISI 12L14 free cutting steel in turning process was carried
out with the emphasis on the optimal workpiece through the quality of surface
roughness. In this work, the performance of cutting inserts in the market and the
newly developed cutting tools was investigated in terms of cutting forces and
surface roughness (Ry). In the first phase, the selection of currently available
cutting tools were done and modeled. Cutting forces simulation using AdvantEdge
software was performed in determining the cutting tool-workpiece force
interactions. In the second phase, the cutting tool-force interactions were studied
and results revealed that tool geometry’s rake angle (γ) and cutting regimes such
as depth of cut (ap) and feed rate (fr) gave significant impacts to the cutting forces
(tangential force, radial force, and feed force) and Ry. A negative rake angle led to
higher cutting forces compared to a positive rake angle. In third phase, a new
proposed design of cutting tool was fabricated and tested according to rough and
finish cutting conditions. Results showed that tool geometries of rake angle,
inclination angle, and major (Kr1) and minor cutting tool’s angle (Kr2) had significant
influences on cutting forces and Ry. In the fourth phase, the tool’s validation
experiments were performed and the optimization was done by employing Taguchi
method. The newly optimized tool cutter geometry was obtained at Kr1 of 60 and
90, Kr2 of +3, rake angle of +10, and the inclination angle of -3. It was revealed
that ap and fr gave a significant impact on surface roughness. As ap and fr
increased, Ry also increased except for setting parameters when ap was below
than minimum chip thickness (Hmin). In the final phase, the performance of the
newly developed cutting tool, in terms of Ry indicated that there was a significant difference between travel lengths and the progression of surface roughness
correspond to tool wear or tool’s performance from 0 mm to 1560 mm (until tool
breakage). However, none of the surface roughness results showed Ry more than
6.3. Additionally, cutting forces tend to increase with the increase of depth of cut
(ap) when ap was higher than 1.15 mm. The feed force magnitude was almost
similar to radial cutting force. However, the cutting force components started to
deviate when the depth of cut was more than 1.15 mm whereby radial force slightly
decreased with the increasing depth of cut. The effect of the combination of two
cutting edges of the newly developed cutting tool could be the reason for radial
force reduction. Hence, the newly developed tool was shown capable to produce
final surface roughness within an acceptable range. The newly developed cutting
tool demonstrated a great potential for turning operation market. |
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