Abstract
This research work presents a numerical study of the orthogonal cutting process employing a finite element approach to optimize dry machining of aluminium alloy 2024. The main objective of the research work is to perform three-dimensional finite element simulations for a better understanding of temperature distribution and residual stresses development in the workpiece and tool regions along depth of cut direction. While, two-dimensional models don't predict true picture of aforesaid parameters along cutting depth due to material's out of plane flow and deformation. In the present study, effects of tool rake angles (7 degrees, 14 degrees, 21 degrees) and cutting speeds (200, 400, 800m/min) upon variations in chip geometry at various sections along workpiece width (depth of cut) have been discussed at large. Furthermore, cutting forces and tool-workpiece temperature profiles are also in depth analysed. The findings will lead the manufacturers to better decide post machining processes like heat treatment, deburring, surface treatments, etc. The results showed that a combination of a rake angle of 14 degrees at cutting velocity of 800m/min produces serrated chip segments with relatively moderate cutting forces in comparison to other parametric combinations. The efficacy of the presented finite element model is verified by comparing the numerically obtained results with experimental ones.