Simulation and Optimization of Von-Mises Stress and Tip Deformation for Single Point Cutting Tool Geometry during Turning

The study aimed to quantify the values of von-mises stress and tip deformation of single point cutting tools of different tool geometries. Pro e Creo 5.0 was used for modeling the cutting tools and simulations were carried out through ANSYS 14.5. Three different materials for cutting tools namely, Cubic Boron Nitride (CBN), High-Speed Steel (HSS), and Gray cast iron having rake angles in the range of 1º–6º, 10º–15º and 20º–25º, respectively were taken for analyses. The rake angles were varied with a unit increment under the considered ranges with corresponding edge radii of 0.25, 0.20, 0.15, 0.10, 0.05, and 0.01 mm for each tool material. The cutting force was constant at 100 N considering engineering stress. The cutting speed of 2.54 m/s and a feed rate of 0.25 mm/revolutions were taken for the simulations of the cutting tool models. The minimum von-mises stress and tip deformation for CBN, HSS, and gray cast iron cutting tools were obtained at an edge radius of 0.15 mm having rake angles of 3º, 12º, and 22º, respectively. The resulted values have provided an estimation for von-mises stress and tip deformation thereby, assisting in improving the machinability, saving energy requirements, and preventing tool failures.