Affiliation:
1. School of Mechanical, Chemical and Materials Engineering, Adama Science and Technology University, Adama, Ethiopia
2. Centre of Excellence for Advanced Manufacturing Engineering, Adama Science and Technology University, Adama, Ethiopia
Abstract
This paper focuses on finite element (FE) modeling using a Lagrangian approach with the ABAQUS/Explicit code to simulate the morphology of CSN 12050 carbon steel chips obtained using different tool rake and flank angles. The cutting operation was performed with a 3D model setup based on the cutting tool to determine the impact of the tool rake and flank angles on the total energy ( ETOTAL), the von Mises stresses, and the cutting force. In these simulations, using adaptive meshing for the tool, 0°, 5° and 10° rake angles, 0° and 6° flank angles, and 0.2-mm and 0.5-mm cut depths were considered as process parameters and the continuous chip morphology was predicted. The tool with 10° rake and 6° flank angles projected moderate machined surface integrity. The FE analysis tool predicted increased von Mises stresses and reduced cutting forces with the 10° rake and 6° flank angles. The maximum ETOTAL and cutting force were obtained for both cut depths when using a tool with 0° and 5° angles. Additionally, experimental results for the mechanical morphology properties of untreated, annealed and recrystallized CSN 12050 carbon steel chips showed that the predicted and experimental chip morphologies agreed well.