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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 O m Malaysia
JULY 2015
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 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.
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 e l e m
(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 80 - 120
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.
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