Investigation and finite element simulation on the MRR and tool wear of aluminium silicon alloy during turning process

Abstract

Abstract In this study tool wear, cutting zone temperature, cutting forces, and material removal rate (MRR) were analysed using three different coating materials during the turning of high silicon aluminium alloy. The results that are derived on coating thickness were analysed in terms of specific coating materials from the proposed numerical investigation. Feed rate was also analysed with respect to output performance on tool wear, cutting temperature, MRR, and cutting forces. Decrease of 90% wear depth on the work piece was confirmed from titanium carbide coated with 3 microns (μm) coated tool and compared with Al2O3 coated tool during the comparison study between coated tools. Cutting forces were determined with proper care and close observation. The highest tool wear of 0.00461 mm was observed using Al2O3 coated tool thickness of 5 microns (μm). The lowest tool wear of 0.00043 mm was observed using TiC coated tool thickness of 3 microns (μm) with minimum cutting force of 74.31 N and also the highest MRR was obtained in the same. It was evident from the observation that the reduction of forces occurred using 2 microns (μm) coated tool on Al2O3leading to the drastic reduction in the thickness up to 67%. The value again reduced when compared with titanium carbide tool on the work piece metal. The analysis established the minimization of tool wear, cutting force, cutting temperature due to lower feed rates. But there was an increase in case of MRR due to lower feed rates. Al2O3 coated cutting tool insert which has maximum tool wear was chosen for the experiment work and the simulations were carried out using Deform2D software. Tool wear length was compared by using SEM images and tool wear was discussed.