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Materials Today: Proceedings 5 (2018) 8364–8373 www.materialstoday.com/proceedings

IMME17

Finite Element Modeling and Machining of Al 7075

Using Coated Cutting Tools
D.Sreeramulu,*, C.J.Rao, Y.Sagar, M.Venkatesh
Aditya Institute of Technology and Management,Tekkali,Srikakulam, 532201,India

Abstract

During machining operation, friction between work piece-cutting tool and cutting tool-chip interfaces results high
temperature on the cutting tool. The effect of thus generated heat leads to shorter tool life, higher surface roughness and lowers
the dimensional sensitiveness of work material. This effect is more predominant when machining of difficult-to-cut materials,
due to occurrence of higher heat. In this study aims to simulate a three-dimensional oblique cutting operations using FEM
software (Deform-3D) to study the effects of cutting speed, feed, depth of cut on cutting forces and temperature. The experiments
are performed on a precision lathe and AL 7075-T6 material as a work piece and coated titanium carbide (TiC/Al2O3/TiN) as a
cutting tool materials. The forces have been measured by 4-component KISTLER Dynamometer and temperatures have been
measured by KIMO Infrared sensor thermometer (Spectral response: 8 - 14 µm). The experimental results are compared with the
outputs of finite element temperature model, considering the maximum temperatures at the tool–work piece interface.

© 2017 Elsevier Ltd. All rights reserved.

Selection and/or Peer-review under responsibility of International Conference on Emerging Trends in Materials and
Manufacturing Engineering (IMME17).

Keywords: coated titanium carbide, Al7075,Simulation

1. Introduction

Machining is an essential process of finishing by which jobs are produced to the desired dimensions and
surface finish by gradually removing the excess material from the preformed blank in the form of chips with the
help of cutting tool(s) moved past the work surface(s). The experimental approach to study machining process is

* Corresponding author. Tel.: +91-9490457054

E-mail address:dowlurusreeram@gmail.com

2214-7853 © 2017 Elsevier Ltd. All rights reserved.

Selection and/or Peer-review under responsibility of International Conference on Emerging Trends in Materials and Manufacturing Engineering
(IMME17).
 Sreeramulu et al., / Materials Today: Proceedings 5 (2018) 8364–8373 8365

expensive and time consuming especially when a wide range of parameters included like tool geometry, materials,
cutting conditions and so on. Because of these difficulties alternative approaches developed as mathematical
simulations where numerical methods are used. Among these numerical methods, finite element method is proved
to be useful and widely used.
1.1. Orthogonal cutting & oblique cutting
Two types of cutting are used in analysis of metal cutting mechanics:
 Orthogonal cutting
 Oblique cutting.
In orthogonal cutting, unwanted material is removed from the work piece by a cutting edge that is
perpendicular to the direction of relative motion between tool and the work piece as shown in Fig. 1(a). In
orthogonal cutting, the material removal process is assumed to be uniform along the cutting edge; therefore it is a
two dimensional plane strain problem.
In oblique cutting, the major cutting edge is inclined to direction of the cutting velocity with an inclination
angle as shown in Fig. 1(b).
Although most of the metal cutting operations are oblique, orthogonal cutting has been extensively studied
because of its simplicity and giving good approximations [1].

Fig. 1: Types of cutting: (a) orthogonal cutting (b) Oblique cutting

Finite element method is basically defined as dividing a continuum system to small elements, describes
element properties as matrices and assembles them to reach a system of equations whose solutions give the behavior
of the total system.
1.2. Application of FEM Models
Different applications of FEM models for machining can be divided into six groups: a) tool edge design, b)
tool wear, c) tool coating, d) chip flow, e) burr formation and f) residual stress and surface integrity. The direct
experimental approach to study machining processes is expensive and time consuming. For solving this problem,
the finite element methods are most frequently used. The modeling of tool wear using FEM has advantages over
conventional statistical approach because it requires less experimental effort and it provides useful information such
as deformations, stress, strain and temperature in chip and the work piece, as well as the cutting force, tool stress
and temperature on the tool working under specific cutting parameter [2].
2. Literature review
Metal cutting can be associated with high temperatures in the tool-chip interface zone and hence, the thermal
aspects of the cutting process strongly affect the accuracy of the machining process. The deformation process is
highly concentrated in a very small zone and the temperatures generated in the deformation zones affect both the
tool and the work piece. High cutting temperatures strongly influence on tool wear, tool life, work piece surface
integrity, chip formation mechanism and contribute to the thermal deformation of the cutting tool, which is
considered, amongst others, as the largest source of error in the machining process [1].
The average chip-tool interface temperatures have been experimentally studied using the tool-work thermocouple
technique. Based on the parametric study, a first-order and second -order empirical models of the chip-tool interface
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temperatures has been developed for turning of EN-31 steel alloy with tungsten carbide tools by response surface
methodology coupled with factorial design. The first order and second-order mathematical models are found to be
adequately representing the cutting temperatures [3].
The polycrystalline tool has superior performance in terms of cutting and feed forces and temperatures when
compared to the cemented carbide tool. On average, the cutting and feed forces are lower in the PCD tool for all
cutting speeds when compared to the K10 tool. This has advantages for the machining process because it increases
the tool life. The same is true for the temperature. In the PCD tool, the temperature is always lower for all the
simulated cutting speeds. This also increases the tool life. The temperature measurement methods and the analytical
and numerical models for the prediction of temperature and temperature distribution in metal cutting. FE modeling
and simulation of machining processes is mainly suffering from a lack of the fundamental input data. Therefore,
further effort is required to provide a clear, consistent, well measured and relevant data on material behavior under
conditions of interest [4].The validation of a previously developed finite difference time domain temperature
prediction model is carried out for orthogonal machining process with an IR camera set-up, considering the
temperature distribution in the tool [5].
The objective of this work has been to create reliable FEM models to simulate three-dimensional cutting
operations that can be used in the future for further investigations. That is why we set up two reference models for
three-dimensional cutting operations and proved their reliability by comparing the simulated and experimental
results in terms of chip geometry and cutting load. The final result can be considered to be very good [6].The
temperature generated on the cutting tool and experimental methods for the measurement of temperatures are
reviewed. Special attention has been paid to tool- work thermocouple method and an experimental setup fabricated
to measure the temperature on the cutting tool and work piece junction during metal cutting is described [7].
3. Experimentation

3.1. Experimental setup

The design of experiments has a major effect on the number of experiments needed. Therefore it is essential to
have a proper design of experiments. A L9 33 array was selected in this work so that all the interactions between the
independent variables can be investigated. In this study the three parameters namely cutting speed, feed, depth of cut
of the cutting tool was selected for the experimentation. The range of each parameter was set at three different
levels. Based on L9 33 array, a total of 9 experiments for coated cutting tool(TiC/Al2O3/TiN), each having a
combination of different levels of factors as shown in Table 1 were carried out. The experiments were replicated
thrice to overcome effect on response due to random variation and average values were noted down.

Table 1. Machining parameters and their levels

Machining Parameters Symbol Level 1 Level 2 Level 3

Cutting Speed(m/min) Vc 120 150 180

Feed(mm/rev f 0.105 0.146 0.205

Depth of Cut(mm) d 0.5 1.0 1.5

3.2. Measurement of temperature using infrared thermometer

The Infrared Thermometer KIRAY 300 is a thermometer used to diagnose, inspect and check any temperature.
Thanks to its elaborated optical system with a dual laser sighting, it allows easy and accurate measurements of little
distant targets. The KIRAY 300 instrument has an internal memory which can save up to 100 measurements and
Compatible with thermocouple K probe. Infrared thermometers can measure the surface temperature of an object as
shown in figure 2.
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Fig. 2: Experimental setup used in machining

3.3. Measurement of force using dynamometer

The multi component dynamometer provides dynamic and quasi-static measurement of the 3-orthogonal
components of force (Fx, Fy, Fz) acting from any direction onto the top plate as well as the moments Mz.

3.3.1. Functional principle

The force and the moment Mz acting on the dynamometer are transmitted through the top plate to a 4- component
load washer. This 4-component sensor contains 3 pairs of quartz rings, where by one are sensitive to compression and
the other two are sensitive to shear either in x or in y direction respectively. An additional set of shear sensitive quartz
plates is arranged on such away to yield an electrical charge proportional to the moment Mz acting about the axis of the
sensor. The acting force is directly resolved into its three components. The charges yielded by the quartz plates are
collected with electrodes connected to the connector of the sensor as shown in figure 3.

Fig. 3: Schematic diagram of Kistler Dynamometer

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3.3.2. Dynoware software

It is a general purpose data acquisition and display software package suitable for cutting force and general
dynamometer applications. It is designed to combine the performance of the proven line of Kistler quartz
dynamometers with modern computer technology.
4. Finite element simulation of metal cutting
4.1. Model formulation:
Three main formulations are used in finite element simulation of metal cutting:
1. Lagrangian,
2. Eulerian
3. Arbitrary Lagrangian-Eulerian (ALE).
4.2. FE Software packages and utilization in metal cutting

Researchers usually wrote their own FE codes for specific process such as metal cutting analysis until the mid-
1990s. In recent years, commercial FE packages such as DEFORM 2D/3D, ABAQUS, ADVANTEDGE, LS-DYNA
etc., It has been used excessively in both academic and industrial world for process analysis [8].

4.3. Introduction to deform software

DEFORM (Design Environment for Forming) is a Finite Element Method based system that can be applied to
several manufacturing processes such as forging, rolling, forming, heat treatment process and machining. Deform
has a specific machining module to quickly set up turning, milling, boring and drilling operations. The figure 4
shows that the simulation of process with varying parameters such as speed, feed, depth of cut etc.

Fig. 4: Simulation model and basic cutting parameters

4.4. Problem formulation in FEM

The choice of finite element software is extremely important to determine the quality and accuracy of the
analysis. In this study, DEFORM 3D was used (this software has been exclusively built with machining operations
in mind, thus being optimized for metal cutting operations). It has a user friendly interface and can simulate both 2D
and 3D machining operations with a wide range of materials in the property library. The software uses adaptive
meshing to increase the accuracy of the simulation. Although the user can’t configure the controls of the solver,
DEFORM is a good software that allows fast machining setups because of its simple and clean interface as shown in
figure 5 [9].

4.4.1. Geometry and mesh:

The finite element mesh was generated using DEFORM automatic mesh generation system. Re meshing
parameters, including minimum element size, and parameters for absolute mesh definition are set within the system
can be shown in figure 6 and 7. For these simulations, a minimum element size of 0.02mm was specified
 Sreeramulu et al., / Materials Today: Proceedings 5 (2018) 8364–8373 8369

Fig. 5: simple machining model as input in DEFORM 3D software

Fig.6: Meshed Tool and Work piece Fig. 7: Mesh design of a work piece

4.4.2. Boundary conditions

Heat exchange is defined on the boundaries A-D and D-C. Boundaries A-B and B-C are sufficiently away from
cutting edge therefore their temperature is fixed 28 ºC.
4.5. Software input parameters
4.5.1. Running the simulation
Simulation engine: The simulation engine is the program which actually performs the numerical calculations to
solve the problem. The simulation engine reads input data from the database, and then writes the solution data back
out to the database. As it runs, it creates two user readable files which track its progress.
4.5.2. Post processor
The postprocessor is used to view simulation data after the simulation has been run. The postprocessor features a
graphical user interface to view geometry, field data such as strain, temperature, and stress, and other simulation
data such as die loads. The postprocessor can also be used to extract graphic or numerical data for use in other
applications.
4.5.3. Pre processor
The preprocessor is used to give the input parameters for process condition, tool mesh generation etc.as shown in
Table 2.
5. Results and discussion
5.1.1. Machining parameters used for experimentation
Table 3.shows the numerical values of the various machining parameters (cutting speed, feed, depth of cut), that
have been selected for experimentation for the measurement of temperature and forces. The Al 7075 alloy material
has been used for experimentation and TiC/Al2O3/TiN used as a cutting material.
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Table 2. Required parameters for pre process

PROCESS CONDITIONS TOOL MESH GENERATION

Unit System SI Size ratio 4
Machining Module Turning Minimum element size (mm) 0.02
PROCESS SETUP BOUNDRY CONDITIONS Heat exchange with environment
Surface cutting Speed (m/min) 180,150,120 WORK PIECE SETUP plastic
Feed (mm/rev) 0.105, 0.146, 0.205 WORK PIECE SHAPE
Depth of Cut (mm) 0.5, 1, 1.5 Length of the work piece (mm) 10 mm
PROCESS CONDITIONS WORK PIECE MESH GENERATION
vironment Temperature( C) 28 Size ratio 4
Coolant Not Used Minimum element size (mm) 0.02
Shear Friction Factor 0.5/K10, 0.6-0.7/ TiC/Al2O3/TiN BOUNDRY CONDITIONS Heat exchange with Environment
Heat transfer coefficient of air
11.43 WORK PIECE MATERIAL Aluminum 7075-T6
(w/m2-k)
TOOL SETUP SIMULATION CONTROLS
Insert CNMG 12 04 08 Number of steps 300
Holder PCLNR 16 16 H12 WIDAX Steps Increment to save 15
Side rake angle -5
GENERATE DATABASE
Back rake angle -5
Nose radius (mm) 0.8
Tool material TiC/Al2O3/TiN and K10

Table 3. Machining parameters and their levels

Machining Parameters Symbol Level 1 Level 2 Level 3

Cutting Speed(m/min) Vc 120 150 180

Feed(mm/rev) F 0.105 0.146 0.205

Depth of Cut(mm) D 0.5 1.0 1.5

5.2. Finite element model of chip formation process

The temperatures at tool tip were calculated by changing different depth of cut, feed, and cutting speeds. This
temperature has been applied to analyze the temperature distribution on the tool at different edge, nodes and
elements through finite element analysis, considering heat loss because of conduction in the tool material and
convection with air at ambient temperature. During analysis, it is assumed that work piece does not undergo elastic
deformation and it is allowed to show only plastic behavior. Finite element mesh of work piece is modeled using
5644 nodes and 35320 tetrahedral elements. Deformation zone mesh is modeled very dense as shown in Fig. 8 and
to reduce the calculation time and obtain more accurate results as shown in Table 4 and 5.

Table 4. Experimental Results of measured parameters for TiC/Al2O3/TiN cutting tools

Cutting speed(Vc) Depthof cut(d) Temperature Cutting
ExpNo Feed(f)(mm/rev)
(m/min) (mm) (T)(oC) Force(Fc)(N)
1 120 0.10 0.5 104.6 72.20
2 120 0.15 1.0 84.4 129.49
3 120 0.20 1.5 96 181.58
4 150 0.10 1.0 96.4 96.89
5 150 0.15 1.5 88.2 167.08
6 150 0.20 0.5 84.4 112.18
7 180 0.10 1.5 88.1 104.43
`8 180 0.15 0.5 85.2 88.28
9 180 0.20 1.0 79.1 146.4
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Fig.8: Finite element model of chip formation

Table 5. FEM Results of measured parameters for TiC/Al2O3/TiN cutting tools
Cutting Speed(Vc) Depthof cut(d) Cutting
Exp No Feed(f) mm/rev) Temperature (oC)
(m/min) (mm) Force(Fc)(N)
1 120 0.10 0.5 94.7 66.4
2 120 0.15 1.0 78.2 119.94
3 120 0.20 1.5 86 167.86
4 150 0.10 1.0 82 89.69
5 150 0.15 1.5 74.7 154.80
6 150 0.20 0.5 79.1 98.81
7 180 0.10 1.5 81.9 98.3
8 180 0.15 0.5 75.1 76.28
9 180 0.20 1.0 71.8 129.4

5.3. Validations of experimental model and FE model

5.3.1. Variation of Cutting force with cutting speed at different feeds of TiC/Al203/TiN Cutting tool

Fig. 9,10,11, and 12 shows how the cutting forces evolve with the variation of cutting speed for both TiC
/Al203 / TiN and K10 tools (the simulation was performed in DEFORM 3D).The cutting forces are substantially
lower in TiC / Al203 / TiN .In order to validate the finite element model, the predicted and experimentally measured
cutting forces and highest temperature of the tool- work piece interface were compared. The values obtained by the
finite element model are shown in Fig. 13 and Fig 14. Below figures shows that the predicted maximum cutting
forces in Y direction are 211.81 & 167.86.by FEM and 230.26 N & 181.58N by experiments using coated and
uncoated tools respectively.

Fig 9: Experimental model of TiC/Al203/TiN tool Fig 10: FE model of TiC/Al203/TiN tool
8372 Sreeramulu et al., / Materials Today: Proceedings 5 (2018) 8364–8373

5.3.2. Variation of Cutting force with cutting speed at different depth of cuts of TiC/Al203/TiN Cutting tool

Fig 11: Experimental model of TiC/Al203/TiN tool Fig 12: FE model of TiC/Al203/TiN tool

Fig 13: FEM model using TiC/Al2O3/TiN tool Fig 14: Experimental model using TiC/Al2O3/TiN

Fig. 15 shows how the temperature evolves for both tools (TiC/ Al2O3 /TiN ) with a variation of the cutting
speed. It can be seen that the TiC/Al203/TiN tool has a lower temperature for all cutting speeds. For a cutting speed
of120 m/min, feed of 0.2 mm/rev and depth of cut of 1.5 mm, for example, the temperature in the TiC/ Al2O3 /TiN
reached 96°C [10].

Fig 15: FEM model using TiC/Al2O3/TiN tool

5.3.3. Variation of Temperature with cutting speed at different feeds of TiC/Al203/TiN Cutting tool

Fig 16: Experimental model TiC/Al203/TiN of tool Fig 17: FE model TiC/Al203/TiN of tool
 Sreeramulu et al., / Materials Today: Proceedings 5 (2018) 8364–8373 8373

The Fig. 16, 17, 18 and 19 shows a relation of cutting speed versus temperature at different feeds used in
experimentation work. The inference that can be drawn from the above graph is that when we increase the cutting
speed the temperatures keep on decreasing [11&12].
5.3.4. Variation of Temperature with cutting speed at different depth of cuts of TiC/Al203/TiN Cutting tool

Fig 18: Experimental model TiC/Al203/TiN of tool Fig 19: FE model TiC/Al203/TiN of tool

6. Conclusion
The results obtained in predicting the outputs of cutting operation using well known FEM three dimensional
models have shown and those results are compared with experimental data. One of the advantages of using
numerical simulation instead of experimentation is the ability to predict thermal and mechanical behavior of both the
material and the tool without spending time and money with experimental procedures. Thereby, improving
productivity and reducing costs. However, accuracy of the results obtained with finite element methods depends
mainly on the accuracy of the input values. Thus, understanding how the input data affect the prediction of the FEM
analysis is fundamental, leading the way to more reliable simulation of the machining processes.

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