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Predicting Cutting Force and Primary Shear Behavior in Micro-Textured Tools Assisted Machining of AISI 630: Numerical
Shafahat Ali1, Said Abdallah1, Salman Pervaiz1
1Department of Mechanical and Industrial Engineering, Rochester Institute of Technology-Dubai Campus, Dubai P.O. Box 341055, United Arab Emirates.
Micromachines
|January 21, 2022
Summary
Microgrooves on cutting tools significantly improve tool life in machining super alloys by reducing friction and heat. Rectangular microgrooves showed superior performance, enhancing both machinability and sustainability in cutting processes.
Area of Science:
- Materials Science and Engineering
- Manufacturing Processes
- Tribology
Background:
- High-performance super alloys generate significant heat during cutting, reducing tool life and impacting machinability.
- Conventional cutting fluids, while improving tool life, pose environmental risks due to their non-biodegradable nature.
- Reducing the coefficient of friction (COF) on the cutting tool rake face is key to enhancing tool life and process sustainability.
Purpose of the Study:
- To numerically investigate the effect of microgrooves on cutting tool performance during the orthogonal cutting of AISI 630 Stainless Steel.
- To evaluate the influence of different microgroove geometries (rectangular and triangular) on cutting temperature and tool life.
- To assess the overall machining performance improvement offered by microgrooved cutting tools.
Main Methods:
- Numerical simulations of the orthogonal cutting process were performed.
- The study utilized cutting tools with integrated microgrooves on the rake face.
- Analysis focused on parameters such as cutting temperature, coefficient of friction, and tool life.
Main Results:
- Microgrooves on the cutting tool rake face positively influenced tool life.
- Cutting temperature decreased by approximately 10% with rectangular microgrooves and 7% with triangular microgrooves.
- Rectangular microgrooved tools demonstrated comparatively better overall machining performance.
Conclusions:
- Microgrooved cutting tools offer a sustainable alternative to traditional cutting fluids for improving tool life.
- The implementation of microgrooves effectively reduces cutting temperature and friction, leading to enhanced machinability.
- Rectangular microgrooves present a promising design for optimizing cutting tool performance in machining super alloys.
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