Study of temperature and stresses using finite element analysis in turning of C45 material

Parts machined by high cutting speeds can often exhibit high fatigue strength, increased micro-hardness in the surface layers and plastic deformations, due to the tool cutting edge radius associated with the induced stresses. The changing of rake and clearance angles has an important influence on the chip formation, cutting forces, residual stresses, temperatures in both the workpiece and the tool. International research on the influence of geometric parameters of the tool on the entire cutting process, are of particular importance to understand this process development. The approach of this study, considers the parametric realization of the cutting tool profile - a coated TiC turning chisel, which will be used in the finite element simulation of the orthogonal turning process. Deform 2D application, which is a powerful simulation engine was chosen and allows the correct simulation of the cutting process in real machining conditions. Deform 2D enables the automatically meshing and remeshing generation and also the optimization whenever needed and wherever is required a high accuracy, thereby reducing the overall difficulty of the problem and the computational requirements. Using Lagrangian discretization, the machining process was simulated and made possible to observe and present a series of conclusions and own points of view regarding the temperature distribution at the tool tip and in the workpiece, the effective stresses distribution and the cutting force variation under the rake and clearance angles influences.