Finite Element Analysis of The Influence of Edge Roundness on The Stress and Temperature Fields Induced by High Speed Machining

High speed machining (HSM) may produces parts with substantially higher fatigue strength; increased subsurface micro-hardness and plastic deformation, mostly due to the ploughing of the round cutting tool edge associated with induced stresses, and can have far more superior surface properties than surfaces generated by grinding and polishing. Cutting edge roundness may induce stress and temperature fields on the machined subsurface and influence the finished surface properties as well as tool life. In this paper, a Finite Element Method (FEM) modeling approach with Arbitrary Lagrangian Eulerian (ALE) fully coupled thermal-stress analysis is employed. In order to realistically simulate high speed machining using edge design tools, an FEM model for orthogonal cutting is designed and solution techniques such as adaptive meshing, and explicit dynamics are performed. Work material flow around the round edge-cutting tool is successfully simulated without implementing a chip separation criterion and without the use of a remeshing scheme. FEM simulations for machining-induced stresses by round edge cutting tools are performed for high speed machining of AISI AISI 4340 steel. Once FEM simulations are complete for different edge radii and depth of cuts, tool is unloaded and stresses are relieved. Stress fields are compared with experimentally measured residual stresses obtain from literature. The results indicate that the round edge design tools influence the stress and temperature fields greatly.