THE EFFECT OF TOOL EDGE RADIUS ON CUTTING CONDITIONS BASED ON UPDATED LAGRANGIAN FORMULATION IN FINITE ELEMENT METHOD

Abstract

Tool wear is a significant problem for manufacturing companies and represents a major challenge in their operations, but it is also a way they can gain a competitive advantage. To do this it is important to set up a standard procedure to develop high performing tooling. This thesis outlines how the Finite Element (FE) method can be used to understand and develop tool geometry. FE based simulation, as a numerical method, is a reliable method to assess the performance of a cutting tool before conducting machining tests based on the force and temperature profile predicted by the FE model. Defining a mathematical model which can be used as a built-in algorithm for tool wear prediction is very challenging and time consuming. Instead there is a possibility of using other factors such as stress distribution and temperature profile and correlate them to tool wear. In this research, the performance of different tool edge radius in cutting has been studied through experiments and in parallel Updated Lagrangian Models have been developed through ABAQUS/EXPLICIT for various cutting conditions, and experimental data was used to validate the data that has been generated from the finite element models. These models are very convenient to develop and capable of being applied for other types of material and cutting conditions. Thus, they represent an efficient way to reduce the amount of experiments needed to improve a tooling, the machining process, and thereby provide an effective way to increase the machining productivity of manufacturing companies.