ANALYSIS OF 3D TOOL WEAR FOR TURNING OPERATION BASED ON FINITE ELEMENT METHOD

Turning is probably most important and widely used conventional mechanical processes. In machining, tool wear influences cutting power, machining quality, tool life and machining cost. When tool wear reaches a certain value, increasing cutting force, vibration and cutting temperature cause surface integrity deteriorated and dimension error greater than tolerance. The life of the cutting tool comes to an end. Then the cutting tool must be replaced or ground and the cutting process is interrupted. The cost and time for tool replacement by adjusting the machine tool increases cost and decreases productivity. Hence tool wear relates to the economics of machining and prediction of tool wear is of great significance for the optimization of cutting process. This work presents a modeling and simulation analysis with FEM for CNC turning. The work describes the simulation of finite element 3D turning process. Second it identifies the correlation between experimental results and simulated results. Extensive experimentations, investigators carried out on CNC turning and the details are reported. The objective of present work is to analyze the tool wear of the cutting tool used in the machining operations. The most important part of this work represents the describing of FEM analysis steps: pre-processing, simulating and postprocessing of data for the established machining processes. An analysis of the most important simulation results is made on displacement due to vibration, cutting forces, stresses, chip formation, tool wear and temperature. The carbide insert tools are used for the experimental work. Total fifty four experiments are carried out and the results are plotted in the form of graphs. These graphs show the variation of displacement and flank wear with respect to cutting speed and the various conclusions are drawn from these graphs