Experimentally investigation and mathematical modelling of the cutting forces and mechanical stresses on metal cutting

viEXPERIMENTALLY INVESTIGATION AND MATHEMATICALMODELLING OF THE CUTTING FORCES AND MECHANICALSTRESSES ON METAL CUTTING(Ph. D. Thesis)Abdullah KURTGAZİ UNIVERSITYINSTITUTE OF SCIENCE AND TECHNOLOGYOctober 2006ABSTRACTIn this present study includes the experimentally determination of the cuttingforces which occur during metal cutting, the analysis of the effects of cuttingforces on the cutting tool by means of ANSYS software finding the solutiondepending on the finite element method and the mathematically modelling ofthe primary cutting force and the stresses using the acquired findings. For thispurpose, various cutting experiments were carried out using different cuttingparameters on Inconel 718 and AISI 1117 workpiece materials, and in order toinvestigate the effects of cutting tool geometry, the test results in the literaturefor Inconel 718, AISI 1040 and AISI 4320 were used. The cutting forcesoccurred during metal cutting were measured by 9257B Kistler dynamometer.Three dimensional stress effects of the cutting forces, measured according tocutting parameters by the cutting tests and extracted from the literature, on thecutting tool were analysed by ANSYS software which uses the finite elementmethod. It was seen that the cutting forces and indirectly the cutting parametersinform related to the location and the variation of cutting tool wear. The effectsof the cutting tool geometries, such as tool holder and insert angles and chipbreaker forms, on the stresses were investigated. A practicable mathematicalmodel for the primary cutting force was developed using the primary cuttingforce data measured by cutting tests. A feasible mathematical model wasviideveloped separately with respect to the stress values obtained by ANSYS forevery one of the stress components (normal, shear and von Mises stresses)formed on the cutting tool for Inconel 718 and AISI 1117 used in the cuttingtests. A good agreement between the results of the developed models forprimary cutting force and stress components, and the results of experimentallyobtained primary cutting force and ANSYS stress components were seen.Science Code : 708.3.028Key Words : Metal cutting, cutting forces, cutting tool stresses,ANSYS, modellingPage Number : 266Adviser : Prof. Dr. Ulvi ŞEKER