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Research Papers

Assessment of Microgrooved Cutting Tool in Dry Machining of AISI 1045 Steel

[+] Author and Article Information
Jianfeng Ma

Department of Aerospace &
Mechanical Engineering,
Saint Louis University,
Saint Louis, MO 63103
e-mail: jma15@slu.edu

Nick H. Duong

Department of Aerospace &
Mechanical Engineering,
Saint Louis University,
Saint Louis, MO 63103

Shing Chang, Shuting Lei

Department of Industrial and Manufacturing
Systems Engineering,
Kansas State University,
Manhattan, KS 66506

Yunsong Lian, Jianxin Deng

School of Mechanical Engineering,
Shangdong University,
Jinan 250061, Shandong, China

1Corresponding author.

Contributed by the Manufacturing Engineering Division of ASME for publication in the JOURNAL OF MANUFACTURING SCIENCE AND ENGINEERING. Manuscript received October 17, 2013; final manuscript received December 29, 2014; published online February 16, 2015. Assoc. Editor: Patrick Kwon.

J. Manuf. Sci. Eng 137(3), 031001 (Jun 01, 2015) (9 pages) Paper No: MANU-13-1377; doi: 10.1115/1.4029565 History: Received October 17, 2013; Revised December 29, 2014; Online February 16, 2015

This paper studies the performance of microgrooved cutting tool in dry orthogonal machining of mild steel (AISI 1045 steel) using advantedge finite element simulation. Microgrooves are designed on the rake face of cemented carbide (WC/Co) cutting inserts. The purpose is to examine the effect of microgroove textured tools on machining performance and to compare it with nontextured cutting tools. Specifically, the following groove parameters are examined: groove width, groove depth, and edge distance (the distance from cutting edge to the first groove). Their effects are assessed in terms of the main force, thrust force, and chip–tool contact length. It is found that microgrooved cutting tools generate lower cutting force and thrust force, and consequently lower the energy necessary for machining. The groove width, groove depth, and edge distance all have influence on cutting force in their own ways.

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Figures

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Fig. 1

FEM machining model with a regular cutting tool

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Fig. 2

Textured cutting tool with microgrooves on the rake face

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Fig. 3

Experimental setup for femtosecond laser micromachining

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Fig. 4

Optical image of microgrooves created on tungsten carbide insert

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Fig. 5

Schematic illustration of the setup for machining experiments

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Fig. 6

Chip–tool contact area between regular and microgrooved tool in experiment and simulation. (a) No groove-experiment, (b) microgroove-experiment, (c) no groove-simulation, and (d) microgroove-simulation.

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Fig. 7

Comparison of cutting force between experimental results and simulations

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Fig. 8

Variations of cutting force with groove width (edge distance =50 μm and depth ratio = 3)

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Fig. 9

Chip formation zone and stress distributions (edge distance = 50 μm and depth ratio = 3). (a) Groove width = 70 μm and (b) groove width = 200 μm.

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Fig. 10

Variations of cutting force with edge distance (groove width = 70 μm and depth ratio = 3)

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Fig. 11

Chip formation zone and stress distributions (groove width = 70 μm and depth ratio = 3). (a) Edge distance = 20 μm and (b) edge distance = 200 μm.

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Fig. 12

Distributions of pressure, the stress in the X and Y direction (groove width = 70 μm and depth ratio = 3) (a) pressure for edge distance = 20 μm, (b) pressure for edge distance = 200 μm, (c) stress-XX for edge distance = 20 μm, (d) stress-XX for edge distance = 200 μm, (e) stress-YY for edge distance = 20 μm, and (f) stress-YY for edge distance = 200 μm

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Fig. 13

Variations of cutting force with depth ratio (groove width = 70 μm and edge distance = 50 μm)

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Fig. 14

Chip formation zone and stress distributions (groove width = 70 μm and edge distance = 50 μm). (a) Depth ratio = 1, (b) depth ratio = 4, and (c) depth ratio = 16.

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