UTHM Institutional Repository

Tool life simulation by finite element method (FEM) in hard machining of AISI D2 harden steel

Azizi, Azizun Nusdin (2015) Tool life simulation by finite element method (FEM) in hard machining of AISI D2 harden steel. Masters thesis, Universiti Tun Hussein Onn Malaysia.


Download (3MB)


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.

Item Type: Thesis (Masters)
Subjects: T Technology > TS Manufactures > TS1-154 Manufactures
Depositing User: Normajihan Abd. Rahman
Date Deposited: 31 Jan 2016 06:58
Last Modified: 31 Jan 2016 06:58
URI: http://eprints.uthm.edu.my/id/eprint/7500
Statistic Details: View Download Statistic

Actions (login required)

View Item View Item


Downloads per month over past year