Expert Modelling and Prediction of Von Mises Stresses in High Speed Steel Cutting Tool Using FEM (ANSYS)

In the machining world, development of predictive models is one remedy to reducing tool failure and its associated challenges like reduction in integrity of machined parts, production shutdown and idle time for machine operators. In this research, we want to show how robust the Finite Element (ANSYS) method is, by comparing its predictive capacity to the experimental machining operation. To achieve the scope of the study, Seventeen (17) varying set of experiments were conducted for the cutting tool using the three levels Box-Behnken’s design (BBD) of experiment at varying process parameters of 200-600 rpm spindle speed, 0.05-0.15mm/rev feed rate and 0.5 - 1.5mm depth of cut. During, the orthogonal cutting of AISI 1010 mild steel measuring 200mm length by 44mm diameter, the electrical strain gauge connected to the Electronic strain meter E10 was used to measure the tools’ induced strains from where the equivalent von mises stresses were generated for the research. The finite element software was then used to model the HSS tool for prediction of the concerned response based on the designed matrix generated by the Design Expert. The experimental values were compared with the ANSYS simulated values using the absolute mean percentage error and the reliability plot. At the end, both the experimental and FEM (ANSYS) readings were in close agreements with a mean absolute percentage error of 0.544%. Therefore, this research has clearly shown that ANSYS is a very robust expert tool that can be used to model and predict von mises stresses in HSS cutting tool.

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