Optimization of Cutting Insert Geometry Using Deform-3d: Numerical Simulation and Experimental Validation

In this research work an attempt has been made to minimize flank wear of uncoated carbide inserts while machining AISI 1045 steel by finite element analysis. Tool wear is the predominant factor that causes poor surface finish and is responsible for the dimensional accuracy of the machined surface. The quality of component produced decides the effectiveness and competitiveness of any manufacturing industry. In this analysis, the effect of tool geometries on performance measures of flank wear, surface roughness and cutting forces generated are evaluated. Three levels of cutting insert shape, relief angle and nose radius are chosen. Taguchi’s Design of experiment (DOE) is used to design the experiments. For three parameters and three levels a suitable L9 Orthogonal array is selected. Based on the designed experiment, simulation analysis is carried out using DEFORM-3D, a machining simulation and analysis software and the output quality characteristics are analysed by statistical techniques like Signal-to-Noise (S/N) ratio and Analysis of Variance (ANOVA). A validation finite element simulation is conducted with the obtained optimum tool geometry, which is also verified experimentally. It is observed that the performance of the determined tool geometry provides satisfactory results. (Received in August 2011, accepted in November 2011. This paper was with the authors 1 month for 1 revision.)