Development of a finite element model for prediction of cutting forces in turning of AISI 1040

Abstract

The surface integrity of a machined component determines its quality and performance, and the intricacies of the machining process influence it. Predicting cutting forces allows for identifying conditions that could cause machining disruptions, enabling preventive measures. This research aimed to develop a finite element model for predicting cutting forces and study the effect of cutting parameters on the cutting forces of AISI 1040 steel. AISI 1040 steel was chosen due to its favorable mechanical properties and widespread use in various industrial applications. Specifically, AISI 1040 steel offers good strength, toughness, machinability, and wear resistance, making it an ideal material for analyzing cutting forces. These characteristics make it a good choice for cutting forces analysis. This study used Analysis Systems (Ansys) to model the AISI 1040 steel and to create a 3D cylindrical model. A piezoelectric dynamometer was used to measure the cutting forces to validate the simulation results. Feed rate (f), speed (v), and depth of cut (d) were taken as input variables. The L27 design of the experiment was applied, and results were analysed using Minitab 18 software. The simulation results agreed with empirically measured resultant cutting forces with a mean error of ≤ 4%. The average margin error obtained was ± 4.84 N. From the analysis of variance, speed had the highest contribution (94.96%), followed by feed rate (0.77%), and lastly, depth of cut (0.19%). Empirical model equations were significant, with a probability value of < 0.05. The correlation coefficients R were 99.75% for simulation and 99.81% for experiment results, validating the 3D finite element model. This research provides valuable insights for optimizing machining parameters to enhance surface integrity and performance. The developed model can be used in industrial applications to predict cutting forces, adjust machining conditions to prevent disruptions and vibrations, and improve the efficiency and quality of the machining process for AISI 1040 steel and similar carbon steels. Keywords Analysis Systems, Cutting force, Finite element model, Prediction, Simulation