In this paper, we develop a methodology to determine flow stress at the machining regimes and friction characteristics at the tool-chip interface from the results of orthogonal cutting tests. We utilize metal cutting analysis originally developed by late Oxley and present some improvements. We also evaluate several temperature models in calculating the average temperatures at primary and second...

A three dimensional (3D) fully coupled thermal-mechanical analysis is presented in order to evaluate the influence of certain cutting parameters as well as dual phase microstructure on the orthogonal micro cutting process of steels (in particular, AISI 1045 steel), for which the size of heterogeneities is of the order of magnitude of the uncut chip thickness and tool edge radius. The simulated ...

In this research work an attempt has been made to minimize flank wear of uncoated carbide inserts while machining AISI 1045 steel by finite element analysis. Tool wear is the predominant factor that causes poor surface finish and is responsible for the dimensional accuracy of the machined surface. The quality of component produced decides the effectiveness and competitiveness of any manufacturi...

Abstract Forging dies are crucial in forging to manufacture accurate workpieces. These generally made of AISI H steel series and hardened tempered medium carbon alloy steel. Dies processed by using high-speed milling + polishing or electrical discharge machining polishing. The surface quality the workpiece depends on properties these dies, where roughness, material hardness, wear evolution thei...

Numerical fracture toughness assessment of two types of steel, AISI 420 and AISI 431, has been conducted in this paper. The J-integral is chosen as a criterion for fracture behaviour comparison of compact type (CT) specimens made of investigated materials. The values of J-integral are determined through a newly developed algorithm using finite element (FE) stress analysis results of numerically...

In this paper, predictive modeling of cutting and ploughing forces, stress distributions on tool faces, and temperature distributions in the presence of tool flank wear are presented. The analytical and thermal modeling of orthogonal cutting that is introduced in Part I of the paper is extended for worn tool case in order to study the effect of flank wear on the predictions. Work material const...

This article presents an experimental investigation and statistical analysis of the effects cutting conditions on machining performance AISI 1045 steel using a wiper-shaped insert. Experimental findings are used to compare obtained wiper inserts with those conventional round-nose as recently reported in literature. In addition, process conditions, namely speed, feed rate, depth cut, analyzed or...