Numerical simulation of two tool turning process

Double tool turning process is used to improve productivity. A 2D finite element model was developed using commercially available finite element analysis software Abaqus 6.13. The workpiece and the cutting tool materials are modelled as elasto-plastic and elastic material respectively. Johnson-Cook damage criterion was used for chip separation. The friction between the cutting tool and the workpiece is modelled based on penalty contact approach. The coefficient of friction between the chip and the first and second cutting tool was taken as 0.8 and 0.6 respectively. In this numerical investigation the effect tool separation distance over the cutting force, feed force and cutting temperature were studied. Three different tool separation distances were considered. The simulation result shows that cutting force and feed force of the front cutting tool and the rear cutting tool do not change appreciably with the variation of the tool separation distance. It was revealed that the temperature rise of the work material due to machining by two cutting tool is well below the recrystallization temperature. Hence the forces on front and rear cutting tool remain same for various tool separation distances. It was also observed that the cutting temperatures remained unchanged for the various tool separation distances