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Self-Propelled Rotary Tools in Hard Turning: Analysis and Optimization via Finite Element Models
Usama Umer1, Syed Hammad Mian1, Muneer Khan Mohammed1
1Advanced Manufacturing Institute, King Saud University, Riyadh 11421, Saudi Arabia.
Materials (Basel, Switzerland)
|December 23, 2022
Summary
This study uses 3D finite element (FE) models to analyze self-propelled rotary tool (SPRT) performance in hard turning. Optimized parameters minimize tool stress and temperature for efficient material removal.
Area of Science:
- Manufacturing Engineering
- Materials Science
- Computational Mechanics
Background:
- Hard turning is a critical manufacturing process for hardened steels.
- Self-Propelled Rotary Tools (SPRTs) offer potential advantages in hard turning applications.
- Accurate modeling is essential for understanding and optimizing the complex phenomena involved in hard turning.
Purpose of the Study:
- To develop and verify 3D finite element (FE) models for simulating self-propelled rotary tool (SPRT) performance in hard turning.
- To analyze the influence of key process parameters on cutting forces, temperatures, and stresses.
- To optimize the hard turning process for minimized tool stress and temperature while considering material removal rate (MRR) and specific cutting energy.
Main Methods:
- Development of coupled temperature-displacement 3D finite element (FE) models with an explicit time-integration scheme.
- Experimental verification of the FE models using hard turning tests on AISI 4340 steel with an SPRT.
- Application of a Central Composite Design (CCD-25) matrix to study the effects of cutting speed, feed rate, depth of cut, and inclination angle.
- Generation of Gaussian process-based response surfaces for predicting process performance.
- Conducting an optimization study to identify optimal process parameters.
Main Results:
- The FE models accurately predict chip morphology, cutting forces, stresses, and temperatures, validated by experimental data.
- Analysis revealed the significant impact of process parameters on SPRT performance during hard turning.
- Response surface methodology enabled prediction of performance variables for un-tested parameter combinations.
- Optimized process parameters were identified, balancing tool integrity with productivity.
Conclusions:
- 3D FE modeling provides a reliable approach for investigating SPRT hard turning processes.
- The study successfully identified optimal process parameters that minimize tool stress and temperature.
- Findings contribute to the enhanced understanding and optimization of advanced machining techniques for hard materials.
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