ISSN 2348–2370

Vol.08,Issue.03,
March-2016,
Pages:0570-0572

www.ijatir.org

Effect of Machining Parameters on Residual Stresses and Temperature

In Turning Operation: A Numerical Study
U. VISHNUJA1, MANU RAVURI2
1
PG Scholar, Dept of MECH, Madanapalle Institute of Technology and Science (MITS), AP, India,
E-mail: vishnujaumapathy@gmail.com.
2
Assistant Professor, Dept of MECH, Madanapalle Institute of Technology and Science (MITS), AP, India.

Abstract: Machining is a dynamic process and is a non
linear response. Machining involves high strain at high
temperatures. In machining operation internal residual
stresses are formed and analysis of these stresses is
becoming objectives of present day research. Residual
stresses are the stress state which occurs in a body after all
external loads are removed. To characterize the residual
stresses in machining operation in an industry, we have to
perform cutting tests by varying cutting conditions (cutting
speed, feed, and depth of cut). Experimental analysis on this
process is to study on residual stresses is time consuming
and is expensive. By using FEA, it provides a basic
knowledge of fundamental mechanisms in tool wear of chip
formation, tool chip interface etc. FEA can measure the
process parameters which are difficult to measure directly
during cutting operation such as residual stress, chip
temperature and chip sliding velocity, etc. Aim of this study
is investigating on effect of input parameters on formation of
surface and sub surface (residual stresses), tool chip
interface temperature in turning process by using FEM tool
(deform 3d) to study the dynamic non linear problem.
and feed, it defines the width of cut, uncut chip thickness,
and tool life, so cutting tool geometry is important[6].
Studied the effect of cutting parameters on surface roughness
of AISI 4340 (coated with high strength low alloy steel ,with
coated carbide insert during hard turning[7]. Depth of cut
and feed of work piece depends on the work piece hardness
and tool material, depth of cut is consistent with amount of
stock to be removed[8].
II. MATERIAL
AISI 1045 Steel is medium tensile steel. It has tensile
strength of 570-700mpa and Brinell hardness ranging
between 170 and210.
TABLE I:

Keywords: FEA, Sub Surface, FEM Models.
I. INTRODUCTION
Residual stresses occur in a body after all external loads
are removed; it is important parameter because it has direct
effect on machined component fatigue life. A finite element
method could be a good tool for selecting the prefect
working cutting parameters, which induce a limitation of the
residual stress state [1]. Used 2d fem as a tool to understand
basics of turning process ,cutting conditions, effect of tool
geometry ,turning variables are predicted with accuracy
[2].Used 3-d finite element method to study the effects of
cutting edge micro geometry on tool forces, a brief study
and experimental study on wears of tool inserts[3].
Calculated experimentally cutting speed on resultant forces
and surface roughness in hard turning AISI H13 [4].
Clearance angle should be provided adequately otherwise it
reduces to surface finish of tool, and tool life ,if clearance
angle is too large it may reduce tool strength. Proper edge
radiusing will improve the strength[5]. Cutting edge of tool
effects the cutting process because, for a given cutting depth
Copyright @ 2016 IJATIR. All rights reserved.
DEFORM-3D: DEFORM-3D software is used to
simulate the turning process, which is based on the
lagrangian equation .The software is used to simulate the
effects of the edge preparations on temperatures , tool wear ,
effective strains and stresses in machining of AISI 1045 steel
. Deform-3D system has
 Archard’s model
 Usui’s model
Usui’s model is used for machining applications ((i.e)
compute insert wear. Archard’s model can used for either
isothermal or non-isothermal runs. Usui’s model can be run
only be used with non-isothermal run as it required interface
temperature calculations.
Applications: Applications of FEM models for machining
can be divided into six groups: 1) tool wear 2) tool edge
design, 3) chip flow 4) tool coating 5) burr formation and
6) residual stress and Surface integrity. The direct approach
of experimental study in machining processes is expensive
and Consumes long time. So, finite element method is used
 U. VISHNUJA, MANU RAVURI
frequently. Fem has many advantages than conventional Side cutting angle (-5)
method of statistical approach, fem provides useful data such Side rake angle (-5)
as stresses, strain, cutting force, tool wear, temperature etc. Back rake angle (-5)
Usui’s equation includes three variables: Sliding velocity
between the cutting tool and TOOL MESH:
chip, tool temperature and normal pressure on tool face. Relative mesh=30,000
These variables can be predicted by FEM simulation of Work piece=plastic
cutting process. Therefore Usui’s equation is very practical
for the implementation of tool wear estimation by using
FEM.

(1)
Where ω= tool wear p=interface pressure v=sliding velocity
T=interface temperature (deg) dt= time increment a, b
=experimentally calibrated coefficients.

The workpiece was assumed to be an plastic material. To

account for the strain rate and temperature effects on the
material properties, a velocity-modified temperature is
calculated using the equation:

(2)
where T is the temperature at the point where the properties
are to be determined, ν the Poisson's ratio, the strain rate, and Fig .2. Work piece meshing.
is the strain rate below which the properties of the material
are unaffected by strain rate.

III. INPUT PARAMETERS

Fig.3.

Fig.1. Tool and work piece interface.

TABLE II: Cutting Conditions and Tool Geometry in

DEFORM 3d

Diameter of work piece=30mm

Tool geometry of CNMA432
Base material-WC
Fig .4.
Tool holder –DCKNL

International Journal of Advanced Technology and Innovative Research

Volume.08, IssueNo.03, March-2016, Pages: 0570-0572
 Effect of Machining Parameters on Residual Stresses and Temperature in Turning Operation: A Numerical Study
Fig .5.
Temperature distribution in work piece at various cutting [5]Astakhov, V.P.: Geometry of Single-point Turning Tools
speeds 130,165,200 (m/min) respectively.
IV. RESULTS
For cutting speed 130(m/min) the temperature has been
penetrated to 0.196mm into the work piece and the
temperature which was inside the work piece was reduced
because of air flow or rotatory movement of work piece.
Maximum length of temperature penetrated into the work
piece from cutting edge is 1.24mm shown in fig (3) from
experimental study through deform. For cutting
speed165(m/min)the temperature has been penetrated to
0.210mm into the work piece and the temperature which
was inside the work piece was reduced because of air flow
or rotatory movement of work piece. Maximum length of
temperature penetrated into the work piece from cutting
edge is 1.38mm shown in fig (4) from experimental study
through deform. For cutting speed 200(m/min)the
temperature has been penetrated to 0.302mm into the work
piece and the temperature which was inside the work piece
was reduced because of air flow or rotatory movement of
work piece. Maximum length of temperature penetrated into
the work piece from cutting edge is 0.744mm shown in fig
(5) from experimental study through deform.
Technology (Tehran Polytechnic), 424-Hafez Ave., 15875-
4413 Tehran, Iran.
[2]Ibrahim A. Al-Zkeri,.‖Finite Element Modeling Of Hard
Turing‖, Doctor Dissertation, The Ohio State University,
2007.
[3]Yiğit Karpat and Tuğrul Özel , "3-D FEA Of Hard
Turning: Investigation Of PCBN Cutting Tool Micro-
Geometry Effects". Department Of Industrial and Systems
Engineering Rutgers ,University Piscataway, New Jersey ,
Transactions Of NAMRI/SME ,Volume 35 ,2007.
[4]Tugrul OZel • Tsu-Kong Hsu • Erol Zeren ," Effects
Of Cutting Edge Geometry, Workpiece Hardness, Feed
Rate and Cutting Speed On Surface Roughness and
Forces In Finish Turning Of Hardened AISI H13 Steel",
International Journal Advance Manufacturing Technology
(2005) 25: 262–269.
and Drills—Fundamentals and Practical Applications.
Springer, London (2010)
[6]Astakhov, V.P.; Paulo Davim, J.: Tools (geometry and
material) and tool wear. In: Paulo Davim, J. (ed.)
Machining—Fundamentals and Recent Advances, pp. 29–
57. Springer, London (2008)
[7]R. Suresh, S. Basavarajappa, V. N. Gaitonde and G. L.
Samuel, ―Machinability Investigations on Hardened AISI
4340 Steel Using Coated Carbide Insert,‖ International
Journal of Refractory Metals and Hard Materials, Vol. 33,
2012, pp. 75-86.
[8]G. Schneider, J. Cmfge. Cutting Tool Applications.
GMRS Associates, 2002.

V. CONCLUSION
 At cutting speed 130(m/min) depth of temperature
penetration is 0.196, length of temperature penetration
into work piece from cutting edge is1.24mm.
 At cutting speed 165(m/min) depth of temperature
penetration is 0.210, length of temperature penetration
into work piece from cutting edge is1.387mm.
 At cutting speed 130(m/min) depth of temperature
penetration is 0.302, length of temperature penetration
into work piece from cutting edge is0.74428mm.

VI. REFERENCES
[1]M. Mohammadpour, M.R. Razfar, R. Jalili Saffar,
Numerical investigating the effect of machining parameters
on residual stresses in orthogonal cutting, Department of
Mechanical Engineering, Amirkabir University of

International Journal of Advanced Technology and Innovative Research

Volume.08, IssueNo.03, March-2016, Pages: 0570-0572