The Experimental and Numerical Study of Hexagonal Cutting Of AISI 316L Steel Round Bars

Cutting processes can be used in batch production of polygonal bars with special features. In this paper, a new form of broaching process for cutting of hexagonal bars from raw round bars is discussed. Due to lack of rolled or drawn raw material, the final product is made of AISI 316L stainless steel bars having appropriate initial size. In this method, a fixed die is used as a tool, and by applying pressure to the raw bar and passing it through the die, it is cut hexagonally. To study this process, different empirical tests have been conducted with different dies. Based on the empirical data, the process is simulated by finite element method. To determine optimal features of the tool, the simulation results in the design and development (i.e., tool making) stages have been used. Among the studied rake angles, the 15 degree angle can be introduced as the most suitable rake angle. In order to evaluate the amount of work hardening, micro hardness tests have been carried out. Quality of final surfaces of machined samples in terms of material and angles of the simulated dies were acceptable and experimental measurements indicated a slight increase in micro hardness of surface layers of the samples.