Validation of 3D Finite Element Simulation of Chip Removal Process Performed by Unique Insert Geometry

Abstract

Main aim of our current research activity is experimental and theoretical investigation of cutting process performed by unique insert geometries. The new geometries should affect smaller cutting forces, less vibration, and better surface quality. Other aspect can be the higher productivity. Economical investigation requires single production, which can be realized by micro EDM process. This paper gives summary about preliminary investigation of application of DEFORM 3D software for simulation of chip removal process performed by cutting insert with unique geometry. Fabrication of unique geometry means modification of the rake face in this case. Experiments were carried out on workpiece material AISI1045. Feed rate and cutting velocity were changed; cutting forces (Fc) and surface roughness (Ra) were measured. Exact geometrical model of the modified cutting insert were applied for FEM simulation. Results of numerical simulation and experiments show good agreement.