Effect of cutting parameters on tool life and cutting temperature in milling of AISI 1038 carbon steeL

Abstract

During chip formation process of machining operations, thermo-mechanical loads are generated which can decrease life of cutting tool and quality of machined components. As a result, analysing the cutting temperatures and cutting tool life during milling operations can enhance productivity in process of part manufacturing using CNC machine tools. To predict the cutting tool life and cutting temperature during machining operations of AISI 1038 Carbon Steel, an application of the virtual machining system is developed. The impact of machining parameters such as cutting speed, feed rate and depth of cut on the cutting tool life and temperature are investigated in order to enhance productivity of milling operations. The modified Johnson–Cook model is used to investigate the combined influence of strain rate and deformation temperature on yield stress during alloy milling operations. Finite element analysis of milling operations is implemented to obtain the cutting temperature of the milling tool during the chip formation process. Then, cutting tool life during milling operations is predicted in order to be analyzed and maximized. The results of virtual machining system in prediction of cutting temperature as well as life of cutting tool are compared with the experimental results in order to validate the developed methodology in the study. So, an advanced virtual machining system is developed in the study in order to decrease cutting temperatures and increase cutting tool life in terms of efficiency enhancement of part production using milling operation.