Numerical Prediction of the Performance of Chamfered and Sharp Cutting Tools during Orthogonal Cutting of AISI 1045 Steel

This paper presents a numerical investigation of the effects of chamfered and sharp cemented carbide tools using finite element method-based DEFORM-2D software and cutting parameters on different machining characteristics during the orthogonal cutting of AISI 1045 steel. The objective is to study the interactions between chamfer width, chamfer angle, sharp angle and the cutting speed and feed rate on the cutting temperature, effective stress and wear depth. These effects were investigated statistically using the analysis of variance (ANOVA) test. The obtained numerical results showed that for the chamfer tool, high values of temperature, stress and wear depth were obtained for chamfer widths of 0.35 mm and 0.45 mm. In terms of combined influences, for the cutting temperature and stress, a strong interaction between the cutting speed and chamfer width was obtained. For the sharp tool design, and in terms of temperature, strong interactions are mostly observed between cutting speeds and feed rates. The ANOVA showed that for both chamfer and sharp tools, the feed rate, the cutting speed and their interactions are the most significant parameters that influence temperature and stress.