Performance of coated tool having undulating surface structures.

Abstract

This paper presents results of a study on the effects of both tool surface profile and friction coefficient on cutting tool during chip formation processes. The computational procedure for modelling in the study involved simulating orthogonal metal machining with a tungsten carbide toolhaving undulating surface topography and coated with titanium nitride. A series of finite element simulations were performed according to Largrangian-Eulerian formulations. An arbitrary Largrangian-Eulerian (ALE) formulation is used because it combines both advantages of Eulerian and Lagrangian representations in a single description and it helps to reduce finite element mesh distortions. The machining parameters were: 1 mm depth of cut, with a feed-rate of 0.4 mm/rev and cutting velocity of 325 m/min. Furthermore, it was ascertained that the maximum temperature reached, the contact length, the shear angle, and the cutting force were dependant on the coefficient of friction (µ). The coefficient of friction used in this study were; 0.3 and 0.4.It was observed that a thin film of coatingplays a great part in tool life and chip formation.

Keywords: Simulation, modelling, orthogonal, metal machining, friction, coefficient, Von Misses