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Expert Modelling and Prediction of Von Mises Stresses in High Speed Steel Cutting Tool Using FEM (ANSYS)

Year 2021, Volume: 9 Issue: 3, 397 - 402, 30.09.2021
https://doi.org/10.21541/apjes.741439

Abstract

In the machining world, development of predictive models is one remedy to reducing tool failure and its associated challenges like reduction in integrity of machined parts, production shutdown and idle time for machine operators. In this research, we want to show how robust the Finite Element (ANSYS) method is, by comparing its predictive capacity to the experimental machining operation. To achieve the scope of the study, Seventeen (17) varying set of experiments were conducted for the cutting tool using the three levels Box-Behnken’s design (BBD) of experiment at varying process parameters of 200-600 rpm spindle speed, 0.05-0.15mm/rev feed rate and 0.5 - 1.5mm depth of cut. During, the orthogonal cutting of AISI 1010 mild steel measuring 200mm length by 44mm diameter, the electrical strain gauge connected to the Electronic strain meter E10 was used to measure the tools’ induced strains from where the equivalent von mises stresses were generated for the research. The finite element software was then used to model the HSS tool for prediction of the concerned response based on the designed matrix generated by the Design Expert. The experimental values were compared with the ANSYS simulated values using the absolute mean percentage error and the reliability plot. At the end, both the experimental and FEM (ANSYS) readings were in close agreements with a mean absolute percentage error of 0.544%. Therefore, this research has clearly shown that ANSYS is a very robust expert tool that can be used to model and predict von mises stresses in HSS cutting tool.

References

  • [1]. Lazoglu, L. and Altintas, Y. (2002) Prediction of tool chip temperature in continuous and interrupted machining. Int. J. Mach. Tools Manufacture. Vol. 42, PP. 1011-1022.
  • [2]. Lawani, D. I., Mehta, N. K and Jain, P. K (2008) Experimental Investigations of Cutting Parameters Influence on Cutting Forces and Surface Roughness in Finish Hard Turning of 250 Steel. Journal of Materials Processing and Technology, Vol. 206, PP. 167-179.
  • [3]. Ozel, T. and Zeren, E. (2004) “Determination of Work Material Flow Stress and Friction For FEA Of Machining Using Orthogonal Tests”. Journal of Material Processing Technology, PP. 153-154, & 1019-1025.
  • [4]. Yen, Y. C., Sohner J., Weule H., Schmidt J. and Altan T. (2003)Estimation of Tool Wear of Carbide Tool in Orthogonal Cutting using Finite Element Method Simulation, Machining Science and Technology, Vol. 6, PP. 467-486.
  • [5].Maranhao C. and Davim J. P. (2011). “The Role Of Flow Stress And Friction Coefficient In Fem Analysis Of Machining: A Review”. Rev.Adv. Mater. Sci. 30 (2012) 184-188
  • [6]. Outeiro, J. C., Pina, J. C., M’saoubi, R., Pusauec, .F and Jawahir, I.S. (2008) Analysis Of Residual Stresses Induced by Dry Turning of Difficult-To-Machine Materials. CIRP Annals – Manufacturing Technology, Vol. 57, Pp. 77-80.
  • [7]. Altan, T. and Semiatim (2012) Measurement and Interpretation of Flow Stress Data for the Simulation of Metal-Forming Processes. Air Force Research Laboratory, Materials and Manufacturing Directorate, Ohio. The Ohio State University Columbus, Oh.
  • [8]. Grzesik and Wanat (2006) Influence of Tool Wear on Surface Roughness in Hard Turning using different Shaped Ceramic Tools Wear, Vol. 265, PP. 327-335.
  • [9]. Chou, K. Y., Evans, J. C. and Barash, M. M. (2002) Experimental Investigation on CBN Turning of Hardened AISI 52100 Steel. Journal of Materials Processing Technology, Vol.124, PP. 274-283.
  • [10]. Benga, G. C and Abrao, A. M. (2013)Turning of Hardened 100 Cr 6 Bearing Steel with Ceramic and PCBN Cutting Tools. Journal of Materials Processing Technology, Vol.143-144, PP. 237-241.
  • [11]. Collins Eruogun Etin-osa and Joseph Ifeanyi Achebo. (2017). Analysis of Optimum Butt Welded Joint for Mild Steel Components Using FEM (ANSYS). American Journal of Naval Architecture and Marine Engineering DOI: 10.11648/j.aas.20170206.12
  • [12]. Sharma, A.V.N.I., Raji, Satyanarayana, Gopichand, A. and Subbaiah, K.V (2012) Optimization of cutting parameters on mild steel with HSS and Cemented Carbide tipped tools using ANN. International journal of Research in Engineering and Technology. ISSN2319-1163, Vol. 1, PP.1-4.
  • [13]. Ozel, Trugrul, And Taylan, Altan. (2000) Determination of Work Piece Flow Stress and Friction at the Chip-Tool Contact for High-Speed Cutting. International Journal of Machine Tools and Manufacture, Vol. 40, PP. 133-152.

EXPERT MODELLING AND PREDICTION OF VON MISES STRESSES IN HIGH SPEED STEEL CUTTING TOOL USING FEM (ANSYS)

Year 2021, Volume: 9 Issue: 3, 397 - 402, 30.09.2021
https://doi.org/10.21541/apjes.741439

Abstract

In the machining world, development of predictive models is one remedy to reducing tool failure and its associated challenges like reduction in integrity of machined parts, production shutdown and idle time for machine operators.
In this research, we want to show how robust the Finite Element (ANSYS) method is, by comparing its predictive capacity to the experimental machining operation.
To achieve the scope of the study, Seventeen (17) varying set of experiments were conducted for the cutting tool using the three levels Box-Behnken’s design (BBD) of experiment at varying process parameters of 200-600 rpm spindle speed, 0.05-0.15mm/rev feed rate and 0.5 - 1.5mm depth of cut. During, the orthogonal cutting of AISI 1010 mild steel measuring 200mm length by 44mm diameter, the electrical strain gauge connected to the Electronic strain meter E10 was used to measure the tools’ induced strains from where the equivalent von mises stresses were generated for the research. The finite element software was then used to model the HSS tool for prediction of the concerned response based on the designed matrix generated by the Design Expert. The experimental values were compared with the ANSYS simulated values using the absolute mean percentage error and the reliability plot.
At the end, both the experimental and FEM (ANSYS) readings were in close agreements with a mean absolute percentage error of 0.544%. Therefore, this research has clearly shown that ANSYS is a very robust expert tool that can be used to model and predict von mises stresses in HSS cutting tool.

References

  • [1]. Lazoglu, L. and Altintas, Y. (2002) Prediction of tool chip temperature in continuous and interrupted machining. Int. J. Mach. Tools Manufacture. Vol. 42, PP. 1011-1022.
  • [2]. Lawani, D. I., Mehta, N. K and Jain, P. K (2008) Experimental Investigations of Cutting Parameters Influence on Cutting Forces and Surface Roughness in Finish Hard Turning of 250 Steel. Journal of Materials Processing and Technology, Vol. 206, PP. 167-179.
  • [3]. Ozel, T. and Zeren, E. (2004) “Determination of Work Material Flow Stress and Friction For FEA Of Machining Using Orthogonal Tests”. Journal of Material Processing Technology, PP. 153-154, & 1019-1025.
  • [4]. Yen, Y. C., Sohner J., Weule H., Schmidt J. and Altan T. (2003)Estimation of Tool Wear of Carbide Tool in Orthogonal Cutting using Finite Element Method Simulation, Machining Science and Technology, Vol. 6, PP. 467-486.
  • [5].Maranhao C. and Davim J. P. (2011). “The Role Of Flow Stress And Friction Coefficient In Fem Analysis Of Machining: A Review”. Rev.Adv. Mater. Sci. 30 (2012) 184-188
  • [6]. Outeiro, J. C., Pina, J. C., M’saoubi, R., Pusauec, .F and Jawahir, I.S. (2008) Analysis Of Residual Stresses Induced by Dry Turning of Difficult-To-Machine Materials. CIRP Annals – Manufacturing Technology, Vol. 57, Pp. 77-80.
  • [7]. Altan, T. and Semiatim (2012) Measurement and Interpretation of Flow Stress Data for the Simulation of Metal-Forming Processes. Air Force Research Laboratory, Materials and Manufacturing Directorate, Ohio. The Ohio State University Columbus, Oh.
  • [8]. Grzesik and Wanat (2006) Influence of Tool Wear on Surface Roughness in Hard Turning using different Shaped Ceramic Tools Wear, Vol. 265, PP. 327-335.
  • [9]. Chou, K. Y., Evans, J. C. and Barash, M. M. (2002) Experimental Investigation on CBN Turning of Hardened AISI 52100 Steel. Journal of Materials Processing Technology, Vol.124, PP. 274-283.
  • [10]. Benga, G. C and Abrao, A. M. (2013)Turning of Hardened 100 Cr 6 Bearing Steel with Ceramic and PCBN Cutting Tools. Journal of Materials Processing Technology, Vol.143-144, PP. 237-241.
  • [11]. Collins Eruogun Etin-osa and Joseph Ifeanyi Achebo. (2017). Analysis of Optimum Butt Welded Joint for Mild Steel Components Using FEM (ANSYS). American Journal of Naval Architecture and Marine Engineering DOI: 10.11648/j.aas.20170206.12
  • [12]. Sharma, A.V.N.I., Raji, Satyanarayana, Gopichand, A. and Subbaiah, K.V (2012) Optimization of cutting parameters on mild steel with HSS and Cemented Carbide tipped tools using ANN. International journal of Research in Engineering and Technology. ISSN2319-1163, Vol. 1, PP.1-4.
  • [13]. Ozel, Trugrul, And Taylan, Altan. (2000) Determination of Work Piece Flow Stress and Friction at the Chip-Tool Contact for High-Speed Cutting. International Journal of Machine Tools and Manufacture, Vol. 40, PP. 133-152.
There are 13 citations in total.

Details

Primary Language English
Subjects Engineering
Journal Section Articles
Authors

Mercy Ozakpolor 0000-0002-7625-0087

Cyril Aliyegbenoma 0000-0003-0056-7763

Publication Date September 30, 2021
Submission Date May 22, 2020
Published in Issue Year 2021 Volume: 9 Issue: 3

Cite

IEEE M. Ozakpolor and C. Aliyegbenoma, “Expert Modelling and Prediction of Von Mises Stresses in High Speed Steel Cutting Tool Using FEM (ANSYS)”, APJES, vol. 9, no. 3, pp. 397–402, 2021, doi: 10.21541/apjes.741439.