Analysis of the orthogonal cutting model by finite elements method in machining

The aim of this study is to give theoretical information about the orthogonal cutting method; to experimentally examine the effect of cutting parameters such as cutting velocity, feed rate and depth of cut on the cutting force and to analyze the Von-mises stresses and the total deformation created in the cutting tool by the finite element method by the cutting force values obtained from the experiments.Chip removal was carried out from the workpiece made of AISI 1040 material using a TiALN coated hard carbide cutting tool. During the cutting tests, the depth of cut was kept constant at 1 mm; cutting velocity was changed as 100 mm/min, 150 mm/min, 200 mm/min and feed rate as 0,1 mm/tooth, 0,2 mm/tooth, 0,3 mm/tooth, 0,4 mm/tooth and 0,5 mm/tooth. Kistler 9333-A force sensor was used to measure the cutting force on the horizontal axis during cutting. The measured force values were transferred to the computer in Newton by using the Kistler-5877B0 amplifier, data reading card and VNC program. The variation of the obtained cutting force values depending on the cutting parameters is explained with the help of graphics. The cutting force values obtained from the experiments were effected on the tool with the help of the ANSYS package program, and the total deformation and Von-mises stresses at the tip of the tool were analyzed. As a result of the obtained data, the effect of cutting force on total deformation and Von-mises stress is explained. In addition, how the cutting velocity and feed rate affect the total deformation and Von-mises stress in the cutting tool is interpreted.