Analysis the Residual Stress in Single Point Cutting Tool During Turning Operation on AISI 1006: FEM and Artificial Neural Network Methodology

ABSTRACT Residual stresses generated in tool play a very important role during machining process .The functional behavior of tool can be enhanced or affected by residual stresses. To understanding the residual stress imparted by machining is an important aspect of the overall quality of the part. The main objectives of this paper is develop a numerical approach to predict the near surface residual stresses in cutting tool and work piece resulting from turning of AISI 1006 and validate the model with ANN. The FEM Explicit dynamics is used for calculating the residual stress in real time environment. Total L16 experiments were designed by Taguchi method. Three input factors (depth of cut, cutting speed and rack angle) and two responses (stress and strain) selected for simulation work. Optimizations of process parameters were done using design of experiments (DOE) and analysis of variance (ANOVA) for some qualitative outcome. In this study model equations are also generated for further analysis using linear regression modeling technique using Minitab software. An artificial neural network model is using for the analysis and prediction the responses. On the basis of simulation work tool wear is dependent on rack angle. KEYWORDS Artificial Neural Network, ANOVA, DOE, FEM, Modal equation