Prediction of Turning Performance in Various Machining Parameter Using FEM

In recent years, the applications of finite element method (FEM) in metal cutting operations have proved to be effective in studying the cutting process and manufacturing process. The simulation result is useful for both researchers and tool makers to optimize the cutting process by designing new tools. Simulation and modelling were performed in two-dimensional and threedimensional for designing the new component prior to fabricating. These are very useful for reducing time and cost consumption in designing automotive parts. The FEM simulation just only requires computational tool and FEM simulation package. The present work aims to predict of performance three-dimensional orthogonal of cutting operations using FEM software (Deform-3D). Some important information such as cutting force, stress, strain and generated temperature during machining process were studied and analysed. Orthogonal cutting simulations were conducted to study the effect of cutting speed, feed rate and depth of cut on the cutting force, the effective-stress, strain and generated temperature in turning process. FCD 500 (ductile cast iron) was used as the work material and cutting tool was DNMA 432 (uncoated carbide tool, SCEA = 0; BR = -5; SR = -5 and radius angle 55o). The cutting parameters varied were cutting speed (100 m/min, 150 m/min and 200 m/min), feed rate (0.1, 0.25 and 0.4 mm/rev), and depth of cut (DOC) (0.3, 0.6 and 0.9 mm). The performance was showed by the simulation results that show by increasing the cutting speed, it causes decreasing in cutting force, effective stress and strain, but the generated temperature during the chip formation process increases. High value of feed rate resulted in bigger cutting force, stress, strain and generated temperature. In addition, bigger cutting force and high generated temperature occurred at high depth of cut