Numerical simulation of effects of machining parameters and tool geometry using DEFORM-3D: Optimization and experimental validation

This research work focusses on optimization of machining and geometrical parameters during turning AISI 1045 steel using carbide cutting tool insert, by Finite Element Analysis and Taguchi’s Technique. Three levels of cutting speed, feed rate, depth of cut, cutting insert shape, relief angle and nose radius are chosen. A suitable L18 Orthogonal array is selected based on Taguchi’s Design of Experiments (DoE) and the simulation analysis is carried out using DEFORM-3D, machining simulation software and the output quality characteristics such as tool-chip interface temperature, interface pressure, wear depth, cutting forces and tool stress are analyzed by Signal-to-Noise (S/N) ratio. Analysis of Variance is performed to determine the most contributing factor, which shows that cutting insert shape is the most prominent parameter contributing by 37.84%, cutting speed by 13.47% and depth of cut by 11.56%. From the optimum condition evolved, validation is done experimentally and by FEM. It is observed that 18.81% increase in quality characteristics are achieved using the optimum condition.