Expert Modelling and Prediction of Von Mises Stresses in High Speed Steel Cutting Tool Using FEM (ANSYS)

In the machining world, development of predictive models is one remedy to reducing tool failure and its associated challenges like reduction in integrity machined parts, production shutdown idle time for machine operators. this research, we want show how robust Finite Element (ANSYS) method is, by comparing capacity experimental operation. To achieve scope study, Seventeen (17) varying set experiments were conducted cutting using three levels Box-Behnken’s design (BBD) experiment at process parameters 200-600 rpm spindle speed, 0.05-0.15mm/rev feed rate 0.5 - 1.5mm depth cut. During, orthogonal AISI 1010 mild steel measuring 200mm length 44mm diameter, electrical strain gauge connected Electronic meter E10 was used measure tools’ induced strains from where equivalent von mises stresses generated research. The finite element software then model HSS prediction concerned response based on designed matrix Design Expert. values compared with ANSYS simulated absolute mean percentage error reliability plot. At end, both FEM readings close agreements a 0.544%. Therefore, research has clearly shown that very expert can be predict tool.