Influence of the Nose Radius on the Machining Forces Induced during AISI-4140 Hard Turning: A CAD-Based and 3D FEM Approach
Abstract
:1. Introduction
2. Materials and Methods
2.1. CAD-Based Application for Designing Turning Inserts
2.2. CAD-Based Layout of the Turning Process
2.3. Pre-Processing of the 3D FE Turning Model
2.3.1. Configuration of the Insert-Workpiece Interface
2.3.2. Modeling of the Insert-Workpiece Materials
3. Results and Discussion
3.1. Assessment of the Cutting Force Components Using FEM
- The radial force is the component that contributes to the resultant machining force the most. In test number nine, for example, this contribution was approximately 56.6%, 65.3%, and 69.2% for each value of nose radius of 0.40 mm, 0.80 mm, and 1.20 mm, respectively. The same trend was observed in the rest of the tests.
- Any increase in feed rate affects all forces except the feed force. Even though the amount of change is not significant, it cannot be considered negligible either. Specifically, an increase in the feed rate from 0.08 mm/rev to 0.11 mm/rev increased the resultant machining force by about 7.6%, 16.0%, and 7.7% for each nose radius (0.40 mm, 0.80 mm, and 1.20 mm, respectively). Similarly, when the feed rate changed from 0.11 mm/rev to 0.14 mm/rev, the feed rate rose by approximately 10.9%, 13.7%, and 10.4% for the same nose radii, respectively.
- In contrast, the nose radius of the inserts had a notable impact on the generated cutting forces. The main machining force increased by 28% on average when the nose radius of the tool changed from 0.40 mm to 0.80 mm. Furthermore, the tool with the 1.20 mm nose radius produced even higher forces. The change from the 0.80 mm nose radius to the 1.20 mm increased Fmain by 35% on average.
- Finally, any change in cutting speed had a limited effect on the turning forces. A slight decrease in cutting forces was noted as lower cutting speeds were applied. In particular, by lowering cutting speed from 150 m/min to 115 m/min, the decrease was estimated as approximately 4.5% and for the equivalent shift from 115 m/min to 80 m/min, the reduction was found to be close to 3.4%.
3.2. Modelling of the Resultant Cutting Force Using RSM
3.3. Validation of the RSM Based Model
- The nose radius had a strong impact on the resultant turning force. In fact, an increase from 0.40 mm to 1.20 mm almost doubled the resultant force regardless of the conditions.
- Any increase in feed rate acts as increasing the main cutting force, but at a much lower grade compared to the effect of the nose radius.
- Finally, any change in the cutting speed did not seem to have a significant influence on the main cutting force.
4. Conclusions
- Fr is the governing force during hard turning of AISI-4140, which in most cases represents two-thirds of the produced resultant machining force.
- When feed rate changed from 0.08 mm/rev to 0.11 mm/rev Fmain gained an average increase of about 10.4%. Similarly, a shift from 0.11 mm/rev to 0.14 mm/rev increased Fmain by approximately 11.7%, regardless of the nose radius value.
- The nose radius of the cutting edge affects the generated cutting forces substantially. It was highlighted that a higher value of nose radius leads to higher values of cutting forces, and depending on the applied cutting conditions, the increase percentage exceeded 30% in most cases.
- Finally, changing the cutting speed did not seem to influence the main cutting force notably.
Author Contributions
Funding
Conflicts of Interest
References
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Level | Vc (m/min) | f (mm/rev) | re (mm) |
---|---|---|---|
I | 80 | 0.08 | 0.40 |
II | 115 | 0.11 | 0.80 |
III | 150 | 0.14 | 1.20 |
A (MPa) | B (MPa) | C | n | m | T0 (°C) | Tm (°C) |
---|---|---|---|---|---|---|
106 | 1167 | 0.0352 | 0.1424 | 0.763 | 20 | 1547 |
Mechanical Properties | AISI-4140 | Ceramic |
Young’s Modulus (GPa) | 212 @ 20 °C | 415 |
192 @ 300 °C | ||
164 @ 600 °C | ||
Density (kg/m3) | 7850 | 3500 |
Poisson’s ratio | 0.30 | 0.22 |
Hardness (HRC) | 60 | − |
Thermal Properties | AISI-4140 | Ceramic |
Heat capacity (J/kgK) | 362 @ 20 °C | 334 |
446 @ 300 °C | ||
610 @ 600 °C | ||
Thermal expansion (μm/mK) | 11.9 @ 20 °C | 8.4 |
13.6 @ 300 °C | ||
14.9 @ 600 °C | ||
Thermal conductivity (W/mK) | 41.7 @ 20 °C | 7.5 |
41.4 @ 300 °C | ||
34.1 @ 600 °C |
Cutting Parameters | Fmain (N) | ||||||
---|---|---|---|---|---|---|---|
Std Order | Vc (m/min) | f (mm/rev) | ap (mm) | re (mm) | Experiments | FE Model | Relative Error (%) |
1 | 80 | 0.08 | 0.30 | 0.80 | 189.8 | 207.7 | 9.4 |
2 | 80 | 0.11 | 0.30 | 0.80 | 244.6 | 250.2 | 2.3 |
3 | 80 | 0.14 | 0.30 | 0.80 | 282.3 | 264.5 | −6.3 |
4 | 115 | 0.08 | 0.30 | 0.80 | 225.7 | 232.1 | 2.8 |
5 | 115 | 0.11 | 0.30 | 0.80 | 264.1 | 266.2 | 0.8 |
6 | 115 | 0.14 | 0.30 | 0.80 | 300.9 | 281.5 | −6.4 |
7 | 150 | 0.08 | 0.30 | 0.80 | 238.0 | 249.6 | 4.9 |
8 | 150 | 0.11 | 0.30 | 0.80 | 267.7 | 281.2 | 5.1 |
9 | 150 | 0.14 | 0.30 | 0.80 | 316.9 | 320.7 | 1.2 |
Cutting Parameters | Fmain (N) | ||||
---|---|---|---|---|---|
Std Order | Vc (m/min) | F (mm/rev) | re (mm) | FE Model | RegressionModel |
1 | 80 | 0.08 | 0.40 | 182.3 | 176.3 |
2 | 80 | 0.11 | 0.40 | 194.1 | 190.6 |
3 | 80 | 0.14 | 0.40 | 213.6 | 212.9 |
4 | 115 | 0.08 | 0.40 | 186.5 | 182.8 |
5 | 115 | 0.11 | 0.40 | 201.0 | 200.3 |
6 | 115 | 0.14 | 0.40 | 221.3 | 225.8 |
7 | 150 | 0.08 | 0.40 | 190.2 | 190.5 |
8 | 150 | 0.11 | 0.40 | 206.5 | 211.1 |
9 | 150 | 0.14 | 0.40 | 233.7 | 239.8 |
10 | 80 | 0.08 | 0.80 | 207.7 | 236.0 |
11 | 80 | 0.11 | 0.80 | 250.2 | 256.2 |
12 | 80 | 0.14 | 0.80 | 284.5 | 284.5 |
13 | 115 | 0.08 | 0.80 | 232.1 | 241.2 |
14 | 115 | 0.11 | 0.80 | 266.2 | 264.6 |
15 | 115 | 0.14 | 0.80 | 301.5 | 296.1 |
16 | 150 | 0.08 | 0.80 | 249.6 | 247.5 |
17 | 150 | 0.11 | 0.80 | 281.2 | 274.1 |
18 | 150 | 0.14 | 0.80 | 320.7 | 308.8 |
19 | 80 | 0.08 | 1.20 | 319.1 | 313.7 |
20 | 80 | 0.11 | 1.20 | 346.9 | 339.9 |
21 | 80 | 0.14 | 1.20 | 371.3 | 374.3 |
22 | 115 | 0.08 | 1.20 | 323.3 | 317.6 |
23 | 115 | 0.11 | 1.20 | 344.4 | 347.0 |
24 | 115 | 0.14 | 1.20 | 382.6 | 384.5 |
25 | 150 | 0.08 | 1.20 | 322.4 | 322.7 |
26 | 150 | 0.11 | 1.20 | 347.4 | 355.2 |
27 | 150 | 0.14 | 1.20 | 392.3 | 395.9 |
Source | Degree of Freedom | Sum of Squares | Mean Square | f-Value | p-Value |
Regression | 9 | 113,045 | 12,560.6 | 238.87 | 0.000 |
Residual Error | 17 | 894 | 52.6 | ||
Total | 26 | 113,939 | |||
R-sq (adj) = 98.80% | |||||
Term | PE Coefficient | SE Coefficient | t-Value | p-Value | |
Constant | 158.1 | 59.8 | 2.64 | 0.017 | |
V | −0.109 | 0.611 | −0.18 | 0.861 | |
f | −822 | 774 | −1.06 | 0.303 | |
re | 48.8 | 39.5 | 1.24 | 0.233 | |
V2 | 0.00046 | 0.00242 | 0.19 | 0.853 | |
f2 | 4504 | 3289 | 1.37 | 0.189 | |
re2 | 56.6 | 18.5 | 3.06 | 0.007 | |
V × f | 3.03 | 1.99 | 1.52 | 0.147 | |
V × re | −0.093 | 0.150 | −0.62 | 0.540 | |
f × re | 498 | 174 | 2.86 | 0.011 |
Test No. | Simulated Fmain (N) | Predicted Fmain (N) | Relative Error (%) |
---|---|---|---|
I | 197.4 | 189.7 | −3.9 |
II | 242.1 | 257.0 | 6.2 |
III | 316.4 | 341.3 | 7.9 |
IV | 217.6 | 203.1 | −6.6 |
V | 248.8 | 275.6 | 10.8 |
VI | 385.7 | 365.1 | −5.3 |
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Tzotzis, A.; García-Hernández, C.; Huertas-Talón, J.-L.; Kyratsis, P. Influence of the Nose Radius on the Machining Forces Induced during AISI-4140 Hard Turning: A CAD-Based and 3D FEM Approach. Micromachines 2020, 11, 798. https://doi.org/10.3390/mi11090798
Tzotzis A, García-Hernández C, Huertas-Talón J-L, Kyratsis P. Influence of the Nose Radius on the Machining Forces Induced during AISI-4140 Hard Turning: A CAD-Based and 3D FEM Approach. Micromachines. 2020; 11(9):798. https://doi.org/10.3390/mi11090798
Chicago/Turabian StyleTzotzis, Anastasios, César García-Hernández, José-Luis Huertas-Talón, and Panagiotis Kyratsis. 2020. "Influence of the Nose Radius on the Machining Forces Induced during AISI-4140 Hard Turning: A CAD-Based and 3D FEM Approach" Micromachines 11, no. 9: 798. https://doi.org/10.3390/mi11090798
APA StyleTzotzis, A., García-Hernández, C., Huertas-Talón, J.-L., & Kyratsis, P. (2020). Influence of the Nose Radius on the Machining Forces Induced during AISI-4140 Hard Turning: A CAD-Based and 3D FEM Approach. Micromachines, 11(9), 798. https://doi.org/10.3390/mi11090798