Group Members

Mohsin 70099258
Hamza Aslam 70098113
Chaudhry Usama Waheed 70098690
Moeez Talat 70099700

Supervisor:
Abdul Rahim
Proposal Presentation
 Project Title

Effect of cutting speed on chip thickness

and shear angle during orthogonal cutting
of Aluminum Alloy-A numerical
investigation
Contents

 Abstract
 Research Narrative
 Research Novelty 
 Research Objectives and Scope
 Literature Survey
 Research Methodology
(a) Description of how research will be conducted.
(b) Theoretical Studies
Conti….

 Research Outcomes & Deliverables 

 Socio-Economic Benefits of Research

 Research Dissemination Plan 

 Research Timetable
Abstract

 In this research work, the Modelling and simulation of orthogonal

metal cutting of Aluminium 6061-T6 are performed by finite
element method using ABACUS software. Effects of the depth of
cut, cutting speed and tool rake face angle on cutting variables using
the Johnson-Cook and Johnson-Cook damage models. Estimation of
the influence and important process parameters such as cutting
speed, depth of cut, feed, and tool rake angle on the cutting forces in
tool geometries design and optimizing the cutting conditions for a
profitable manufacture of quality machined products.
Research Narrative

By describing the impact of cutting speed on chip

thickness and shear angle during orthogonal cutting
of aluminum alloy, our work on the abacus program
will provide a solution to the issue.
Research Novelty

The goal was to forecast the chip thickness and shear

angle in the machined component at varying feed
rates and cutting speeds while maintaining constant
tool geometry and cutting depth.
Research Objective and Scope

 The goal of the research study is to use computational and

experimental approaches to analyze the chip morphology
in the workpiece (Al-6061-T6)

 To simulate a 2D orthogonal model on Abacus software

Literature survey

 According to orthogonal cutting tests, segmented chips are

created at a certain speed by catastrophic localized shear,
and the machined surface may change depending on the
chip segmentation spacing.
 Segment spacing is a function of surface speed, rake
angle, and depth of cut, and it decreases quickly as it
approaches a limiting point.
Research Outcomes & Deliverables
(a) Description of how research will be conducted

This research will be performed on Abaqus software. In this

study, a fully coupled thermal-mechanical FE model in
ABAQUS SOFTWARE was created to analyse the Al6061-
T6 chip morphology at cutting speeds.
(b) Theoretical Studies

 Cutting speed

 Chips

 Shear angle

 Orthogonal cutting
Research Outcomes & Deliverables

 Abacus will help to simulate the predicted chip

morphology by using an aluminum 6061 model.

 Shear angles were also found to be sensitive to cutting

parameters and increased with the increase of cutting
speed and feed rate.
Socio-economic benefits of research

 Job creation Economics

 growth Reduced

 waste and cost saving

 This technique (ABAQUS) measure different chip locations and

extremely small values of chip thickness in microns
Research Dissemination Plan

We disseminate the plan through:

 Posters Presentations

 Media

 Pamphlets
Research Timetable