TOOL LIFE SIMULATION BY FINITE ELEMENT METHOD (FEM) IN HARD MACHINING OF AISI D2 HAIRDEMD STEEL

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1 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 Om Malaysia JULY 2015

2 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 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.

3 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 elem (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 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.

31 References Arrazola, P.J. and Ozel, T., "Investigations on the effects of friction modeling in finite element simulation of machining," International Journal of Mechanical Sciences, Vol. 52, pp ,2010. Arsecularatne J.A, Zhang L.C, Montros, C. and Mathew P.(2006). On Machining of Hardened AISI 02 steel with PCBN Tools. Journal of Materials Processing Technology 17 1 (2): B2tker M., RGsler J., Siemers C., Finite element simulation of segmented chip formation of Ti-6Al-4V, ASME J. Manuf. Sci. Eng. 124 (2) (2002) Boothroyd, G. & Knight,W.A. Fundamental of Machining and Machine Tools, Second edition, Boca Raton: CRC Press Ceretti E., FEM simulations of segmented chip formation in orthogonal cutting: further improvements, in: Proceedings of the CIRP Intermtiom1 Workshop on Modeling ofmachining Operations, Atlanta, GA, 1998, pp Constantin C., Croitoru S.M., Constantin G., Strhjescu E., FEM Tools For Cutting Process Modelling And simulation U.P.B. Sci. Bull., Series D, Vol. 74, Iss. 4,2012 Ceretti E., Lazzaroni C., Menegardo L., Altan T., Turning simulations using a three- dimensional FEM cock, J. Mater. Process. Technol. 98 (2000) Cockroft, M.G. and Latham, D.J., "Ductility and workability of metals," Journal of Institute of Metals, Vol. 96, pp , Fagan M.J., Finite Element Analysis: Theory and Practice, Longman, New York, ISBN

DESIGN AND DEVELOPMENT OF LOW-COST FRICTION STIR WELDING AHMAD SYAZNI BIN ZAKARIA

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