TOOL LIFE SIMULATION BY FINITE ELEMENT METHOD (FEM) IN

HARD MACHINING OF AISI D2 HAIRDEMD STEEL

AZIZUN NUSDIN BIN AZIZI

A Master's Project Report submitted infblfdlment of the requirement for the

award of the

Master of Mechanical Engineering

Faculty of Mechanical and Manufacturing Engineering Universiti Tun Hussein O m Malaysia

JULY 2015

ABSTRACT

Manufacturing industry in this decade witnesses the emerging of many machining

technologies that have been growing rapidly. One of the challenging reservations is

machining of hard metals. The hard metal materials are widely used in the

engineering space, armaments, tool and die, mining, and manufacturing. Normally,

the hard metal cutting materials (> 45 HRC) is operated by using a grinding machine

or electrical machining (EDM). This study is carried out to reduce the costs, to obtain

short cycle time, low processing steps, high flexibility and to produce of the smooth

surface metals. Most of the hard metals cutting had experienced a difficulty to

optimise the cutting condition with regard to the cost, time and accuracy of work.

Therefore, this research has been directed towards in investigating the tool life of

TiAlN Sandvik PVD coated carbide that use in cutting of hardened steel, AISI D2

(58-62 HRC). In this study, the pyhsical phenomenon of AISI D2 machining was

studied using numerical simulations through the 3D Finite Element Method (FEM)

and it was accomplished by DEFORM 3D software. The main criteria analyzed were

temperature, cutting force, stress and strain. The simulation results obtained were

used to explain the effects of machining parameters on the tool life results that

derived by the previous researchers through the experiment. In the experimental

works, the machining process was carried out using CNC vertical milling machine in

dry condition. The cutting parameters selected were in the range of 80-120 rpm,

stepover 3-5mm and depth of cut was kept constant at 0.5 mrn. Findings show that

the distribution of temperature, stress, strain and force were inversely proportional to

the tool life that experimentally obtained. Finally, the highest acceptable value of

tool life was given by the lowest cutting speed of 80 RPM. It was found that the

results from DEFORM 3D FEM simulations are able to fairly explain and validate

the experimental results obtained by the previous researchers.

ABSTRAK

Dalam industri pembuatan pada dekad ini, banyak teknologi pemesinan telah

berkembang dengan pesatnya. Salah satu kaedah pemesinan yang makin mencabar

adalah pemesinan bahan logam berkerasan tinggi. Bahan logam keras ini banyak

digunakan dalam bidang kejuruteraan angkasa lepas, persenjataan, perlombongan,

pembuatan alat dan acuan dan sebagainya. Kebiasaannya pemotongan bahan logam

keras (>45 HRC) adalah menggunakan mesin pencanai atau pemesinan e l e m

(EDM). Pembangunan ini adalah untuk mendapatkan pengurangan kos, kitaran masa

yang pendek, langkah pemprosesan yang kurang, fleksibiliti yang tinggi clan

akhirnya kemasan permukaaan yang baik. Kebanyakan kerja memesinan bahan

logam keras ini mempmyai masalah dalam melalcukan proses pemotongan yang

paling optimum dari segi kos, masa , proses dan kejituan hasil kerja. Penyelidikan

telah dijalankan untuk menyiasat jangkahayat mata alat Sandvik PVD TiAlN bersalut

Karbida ketika memotong keluli keras AISI D2 (58-62 HRC) dengan menggunakan

mesin kisar menegak CNC, dan memotong dalam keadaaan pemesinan kering.

Parameter memobngan kisar yang dilakukan adalah berkelajuan diantara 80 - 120

pus/min, anjakan bertentang pemotongan 3 - 5 mm, dan kedalaman pemotongan

adalah malar pada 0.5 mm. Dapatan kajian ini menunjukkan bahawa pengagihan

suhu, tekanan, keterikan dan daya adalah berkadar songsang dengan hayat mata alat

yang diperolehi dari ujikaji. Akhir sekali, nilai hayat mata alat tertinggi yang boleh

diterima ditunjukkan oleh kelajuan pemotongan yang paling rendah 80 RPM. Kajian

ini telah mendapati bahawa hasil dari simulasi DEFORM 3D FEM dapat

menjelaskan dan mengesahkan keputusan ujikaji yang diperolehi oleh penyelidik

terdahulu.

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