Analysis of turning chip morphology with various tool geometries using finite element modeling and simulation to optimize product sustainability

Abstract

This paper focuses on finite element (FE) modeling using a Lagrangian approach with the ABAQUS/Explicit code to simulate the morphology of CSN 12050 carbon steel chips obtained using different tool rake and flank angles. The cutting operation was performed with a 3D model setup based on the cutting tool to determine the impact of the tool rake and flank angles on the total energy ( ETOTAL ), the von Mises stresses, and the cutting force. In these simulations, using adaptive meshing for the tool, 0°, 5° and 10° rake angles, 0° and 6° flank angles, and 0.2-mm and 0.5-mm cut depths were considered as process parameters and the continuous chip morphology was predicted. The tool with 10° rake and 6° flank angles projected moderate machined surface integrity. The FE analysis tool predicted increased von Mises stresses and reduced cutting forces with the 10° rake and 6° flank angles. The maximum ETOTAL and cutting force were obtained for both cut depths when using a tool with 0° and 5° angles. Additionally, experimental results for the mechanical morphology properties of untreated, annealed and recrystallized CSN 12050 carbon steel chips showed that the predicted and experimental chip morphologies agreed well.