design and analysis of coated and internal cooled single point cutting...
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Design and Analysis of Coated and Internal Cooled Single Point Cutting
Tool
D Indra Teja1, Dr. Suresh J S2 1, PG Scholar, Department of Mechanical Engineering
2 Professor and HOD, Department of Mechanical Engineering
Ramachandra College of engineering, Eluru, West Godavari (Dist), AP, India. indrateja926@gmail.com
Abstract: Single point cutting tool is most widely used tool in several machining and metal cutting operations.
The work piece material is removed or machined step by step by force which increases temperatures of both work
piece and tool Itself . Where it causes in thermal damage and high tool wear rate. The tool tip may deform
plastically due to high temperature which results in poor accuracy in machining. There are several experiments and
research going on to minimize these temperatures. The main objective of this work is carry to increase the
machining capabilities of single point cutting tool by decreasing temperature using internal cooling and increasing
material strength by adding carbon fibre to ceramic cutting tool and comparing structural forces on it. In this
analysis, a small slot is made to hold external cooling pipe in the single point cutting tool. PTC CREO used as
design software for tool design and ANSYS used as simulation software to simulate different scenarios with
thermal and structural loads and compare results.
Key words: single point cutting tool, cutting forces temperature, ANSYS, CREO PTC, stresses.
1. Introduction
Cutting Tool is a wedge-shaped device that actually removes (shears off) excess material from a preformed blank
in order to obtain desired shape, size and accuracy. While machining or metal cutting operation, the cutter
forcefully compresses a thin layer of material in the workpiece and gradually shears it off. However, to remove
material, three relative motions are necessary
Classification of cutting tools.
Cutting tools can be classified into two groups, as given below.
Single point cutting tool
Multi point cutting tool
Cutting Tools
Single point cutting tool: Single point cutting tool consists of only one main cutting edge that can perform
material removal action at a time in single pass.
Multi Point Cutting Tool: A multi point cutting tool contains more than two main cutting edges that
simultaneously engage in cutting action in a pass.
Single point cutting tool Multi point cutting tool
Turning tool Milling cutter
Shaping tool Reamer
Planning tool Broach
Slotting tool Hob
Boring tool Grinding wheel
The following properties are required for cutting tool
hardness, hot hardness and pressure resistance
bending strength and toughness
inner bonding strength
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Volume IX Issue VII JULY 2020
ISSN : 0950-0707
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wear resistance
oxidation resistance
small prosperity to diffusion and adhesion
abrasion resistance
Advantages of single point cutting tool
Design and fabrication of single point cutter is quite simple less time consuming
such tools are comparatively cheaper
Disadvantages of single point cutting tool
.
a single point cutting tool edge continuosly remains in physically contact with the work material during
machining.sothe tool wear rate is also high and as a result tool life is low.
due to continuous contact, rate of rise in tool temperature is high .this in one hand accelerates tool wear
and other causes thermal damages of the finished and machined surface.
high temperature rise may plasticlly deform the tool tip that can be lead to poor accuracy in machining.
since only one cutting edge takes entire depth of cut(chip load) for a pass, the material remove rate (MRR)
is much lower. thus productivity is poor.
cutting tool materials must be harder than the material of the workpiece , even at high temperature during
the process.
Hss tools presently used in various metal cutting operations . this hss tools coated with aluminium oxide
(AL2O3). aluminium oxide (AL2O3) is reduce rate of flank wear. High hardness beneficial resists abrasion wear.
Retention of hardness at high temperature in the range of 300 to 1000 deg depend on machine parameter and
material to be machined. They all exhibit a decreases with an increases of temperature and decreases the hardness
was pronounced in the case of AL203 mixed with 15% carbon composite material with internal cooling. Increases
in hardness AL2O3 was significantly lower than AL203 mixed with 15% carbon. Al2o3 with 15% carbon tool
provide a slot back side of shank to pass a cooling circuit.
Objectives of internal cooling:
manufacturing of green products particulary used in renewable energy system or continimation free
environment.
green the manufacturing that is reduce pollution and waste by minimize of nature source usage, recycling
and reusing by pass products and reduce emissions.
2. Literature review
Research has been undertaken into measuring the temperatures generated during cutting operations. Investigators
have attempted to measure these cutting temperatures with various techniques.
The main techniques used to evaluate the temperature during machining (tool chip thermocouple, embedded
thermocouple, and thermal radiation method) have been reviewed by Barrow [2] and are discussed below.
Thermocouples have always been a popular transducer used in temperature measurement shown bellow.
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Fig.1 Thermocouple representation
Thermocouples are very rugged and inexpensive and can operate over a wide temperature range. A thermocouple
is created whenever two dissimilar metals touch and the contact point produces a small open-circuit voltage as a
function of temperature.
If these two dissimilar materials are the cutting tool and the workpiece material, then this thermocouple is called a
tool chip or tool work thermocouple.
The tool work thermocouple technique is used to measure the cutting temperatures at the interface between the tool
and the chip.
Standard thermocouples embedded in the cutting tool or workpiece material can be used to measure the
temperature at a single point or at different locations to establish the temperature distribution in the tool.
They can also be positioned at the interface between an indexable insert and the tool holder.
This technique is easy to apply but only measures the mean temperature over the entire contact area [1,3]. High
local or ash temperatures which may occur for a short period of time cannot be observed.
Cozzens et al. [4] use many thermocouples embedded in an aluminium tube.
Temperature measurements were taken at various radial and longitudinal positions in the workpiece as the tool
moved down the tube. From these results, the author develops a temperature distribution model.
This model then accurately predicted the peak temperatures after a coolant was used for the same cutting tests.
In 1958, Reichenbach [5] used infrared thermography to measure the shear plane temperature in a metal chip and
the clearance-face temperature of a cutting tool using photoconductive cells. Several fundamental difficulties were
described in the paper but no solution was offered
3. Methodology
In this work use two different tools one is hss coated with AL203 and hss coated with AL2O3 with 15%
carbon fibre. And providing slot to pass coolant with the help of internal cooling circuit. Study and
compare thermal loads and structural loads of two tools using one parameter.
Modeling the single point cutting tool to be done by using CREO PTC software.
Analysis of single point cutting tool to be done by using ANSYS WORKBENCH.
Fig.2 Test system representation
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CREO PTC: PTC creo parametric offers powerful, reliable, yet to use easy modeling tools that accelerate the
products design process. The software helps to design part and assemblies, create manufacturing drawings,
perform analysis, create renderings and animations and optimize productivity across afull range of other
mechanical design tasks. PTC creo parametric will help design higher quality products faster and allow
communicating more efficiently with manufacturing and your suppliers.
Fig.3 Initial design of single point cutting tool
4. ANSYS Workbench
Finite Element Method:
The finite element method is numerical analysis technique for obtaining approximate solutions to a wide variety of
engineering problems. Because of its diversity and flexibility as an analysis tool, it is receiving much attention in
engineering schools and industries. In more and more engineering situations today, we find that it is necessary to
obtain approximate solutions to problems rather than exact closed form solution.
Fig.4 Modified design of single point cutting tool
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It is not possible to obtain analytical mathematical solutions for many engineering problems. An analytical
solutions is a mathematical expression that gives the values of the desired unknown quantity at any location in the
body, as consequence it is valid for infinite number of location in the body. For problems involving complex
material properties and boundary conditions, the engineer resorts to numerical methods that provide approximate,
but acceptable solutions.
The finite element method has become a powerful tool for the numerical solutions of a wide range of engineering
problems. It has developed simultaneously with the increasing use of the high-speed electronic digital computers
and with the growing emphasis on numerical methods for engineering analysis. This method started as a
generalization of the structural idea to some problems of elastic continuum problem, started in terms of different
equations or as an extrinum problem.
The fundamental areas that have to be learned for working capability of finite element method include:
Matrix algebra.
Solid mechanics.
Variational methods.
Computer skills.
FEA Software – ANSYS
Dr. John Swanson founded ANSYS. Inc in 1970 with a vision to commercialize the concept of computer simulated
engineering, establishing himself as one of the pioneers of Finite Element Analysis (FEA). ANSYS inc. supports
the ongoing development of innovative technology and delivers flexible, enterprise wide engineering systems that
enable companies to solve the full range of analysis problem, maximizing their existing investments insoftware and
hardware. ANSYS Inc. continues its role as a technical innovator. It also supports a process-centric approach to
design and manufacturing, allowing the users to avoid expensive and time-consuming “built and break” cycles.
ANSYS analysis and simulation tools give customers ease-of-use, data compatibility, multi-platform support and
coupled field multi-physics capabilities.
Evolution of ANSYS Program
ANSYS has evolved into multipurpose design analysis software program, recognized around the world for its
many capabilities. Today the program is extremely powerful and easy to use. Each release hosts new and enhanced
capabilities that make the program more flexible, more usable and faster. In this way ANSYS helps engineers
meet the pressures and demands modern product development environment.
Static structural analysis
A static structural analysis calculates the effects of steady loading conditions on a structure, while ignoring inertia
and damping effects, such as those caused by time- varying loads. A static analysis can, however, include steady
inertia loads (such as gravity and rotational velocity), and time-varying loads that can be approximated as static
equivalent loads (such as the static equivalent wind and seismic loads commonly defined in many building codes).
Static analysis is used to determine the displacements, stresses, strains, and forces in structures or components
caused by loads that do not include significant inertia and damping effects. Steady loading and response conditions
are assumed; that is, the loads and the structure’s response are assumed to vary slowly with respect to time.
A static structural analysis can be either linear or nonlinear. All types of nonlinearities are allowed- large
deformations, plasticity, creep, stress stiffening, contact (gap) elements, hyper elastic elements, etc. The topology
module is then selected and linked to structural analysis.
Starting the project
ANSYS Workbench is opened and ‘Static structural’ module is selected. Upon creation a new project schematic
appears as shown in fig.5.
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Fig.5 Project schemata
The following steps are then followed:
Selection of material
The first step is the selection of the material that we use in the project later wards. Upon double clicking the
Engineering materials, the following window appears and then the choice of the materials used for the project can
be made accordingly.
In the current project Structural steel is used to assign for the single point cutting tool and study the process
parameters accordingly.
Fig.6 Engineering materials selection
Analytical Calculation Of Forces On Cutting Tool
For d = 0.4 mm and f = 0.15 mm/rev Fc = 5516 × f0.85 x d0.98 N
Fc= 5516 × 0.150.85 x 0.40.98
Fc = 448.05 N
Where d = Depth of Cut f = Feed rate
Fc = Cutting Force
Average co-efficient of friction on the tool face, μ = 0.7
Rake angle, α = 12
𝛍 =𝐅𝐜𝐭𝐚𝐧𝛂 + 𝐅𝐭
𝐅𝐜 − 𝐅𝐭𝐭𝐚𝐧𝛂
Thrust Force, Ft = 190.11 N
Shear angle φ =𝒓𝒄𝒐𝒔𝜶
𝟏−𝒓𝒔𝒊𝒏𝜶
φ = 32.21°
Normal Force
Fn= Fc sin∅+ Ft cos∅
Fn = 448.05 sin 32.21+190.11 cos 32.21
Fn = 399.67 N
Fn = ~ 400 N
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Material properties
Name:AL2O3
Mass:0.2114 kg
Fig.7 Engineering materials selection
Name:AL203 with 15% of carbon fibre
Mass:0.15478 kg
Fig.8 Engineering materials selection
Imported Geometry
Fig.9 Al2O3
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Fig.10 Al2O3 with 15% of carbon fibre
Meshed geometry
The next step is meshing the whole geometry into small elements. In ANSYS work table, the model of single
point cutting tools is traded to work and then the choice of the mesh element size is selected. Smaller mesh
elements yield to increased accuracy in the solution at the cost of increase in the solver time in both generating the
mesh as well as solving the equations later on. Once the mesh size is selected, mesh is generated using the
‘Generate Mesh’ option. The meshed model resembles as follows. Since topology optimization is being done the
mesh must be very fine and the type of element used is to be Hexagonal mesh. Hence Hex dominant mesh is
introduced with a body sizing of 2mm
Fig.11 Al2O3 with 15% of carbon fibre
Fig.12 Meshed model
Setup
After the mesh is generated, the next step that follows is imparting the boundary conditions to the model.
The following boundary conditions are imparted to the Connecting rod:
1) Fixing one face : Right click on the static structural on the left side and upon right clicking select ‘Fixed
support’. Now select the face that needs to be fixed and then click on ‘apply’.
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2) Imparting load to the model : Right click on the static structural on the left side and upon right clicking
select ‘Force’. Now select the face on which the force need to be applied, specify the magnitude and the
direction of the force and then click on ‘apply’. In this case the load is applied on the circular face, so
select the face on which the force is to be applied. The load applied on the circular face is 400N.
Thermal Loads
Fig.13 Al2O3
Fig.14 Al2O3 with 15% of carbon fibre
Temperature distribution
Fig.15 Al2O3
Max-200 °C ; Min-153.26 °C
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Fig.16 Al2O3 with 15% of carbon fibre
Max-200 °C ; Min-25.26 °C
Heat Flux
Fig.17 Al2O3
Max-0.55W/mm-2 ; Min-0.0009W/mm-2
Fig.18 Al2O3 with 15% of carbon fibre
Max-0.08W/mm-2 ; Min-4.89e-5 W/mm-2
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Structural Loads and Boundary conditions
Fig.19 Al2O3
Force-400N X=direction
Fig.20 Al2O3 with 15% of carbon fibre
Force-400N X-direction
Boundary Conditions
Once the boundary conditions are imparted, the solution is generated by clicking on ‘Solve’. After the solution is
completed, the desired results are update and on the solution pane and the results are evaluated using ‘Evaluate all
results’ tab. Once the results are obtained, individual result is analyzed accordingly. In this project, the stress,
strain, deformation are the desirable results.
Total Deformation
Fig.21 Al2O3
Max-0.0596mm
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Fig.22 Al2O3 with 15% of carbon fibre
Max-0.0011mm
Equivalent Elastic Strain
Fig.23 Al2O3
Max-0.02mm/mm
Fig.24 Al2O3 with 15% of carbon fibre
Max-0.0001mm/mm
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Equivalent Von-Misess Stress
Fig.25 Al2O3
Max-4108.5 MPa
Fig.26 Al2O3 with 15% of carbon fibre
Max-51.409 MPa
Results
Name: Al2O3
Name: Al2O3 with 15% of
carbon fibre
Mass
Temperature
Heat flux
Total deformation
EquivalentElastic Strain
Equivalent Von-Misess Stress
0.2114 kg
Min-153.26 °C
Min-0.0009W/mm-2
Max-0.0596mm
Max-0.02
Max-4108.5 MPa
0.15478 kg
Min-25.26 °C
Min-4.89e-5W/mm2
Max-0.0011mm
Max-0.0001
Max-51.409 MPa
From above results observed that AL203 with 15% carbon fibre better than AL203 at different thermal loads and
structural loads.
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5. Conclusion
It can be observed that temperature of the cutting tool is decreased when it is cooled with help of an external
coolant passed into the created slot in the cutting tool. This decreased temperature of the tool helps for better
cutting quality and increase the tool life.
By comparing the results, we conclude that strength of the ceramic cutting tool (Al2O3) has been improved by
adding of carbon fibre to the cutting tool material. This Al2O3 carbon fibre cutting tool material can increase the
overall tool life, productivity and minimizes the tool breakage.
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ISSN : 0950-0707
Page No : 430
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