Computational Technology Resources - CCC

T. Waqar¹ and S.S. Akhtar^2,3

¹Department of Mechanical Engineering, University of British Columbia, Okanagan, BC, Canada
²Mechanical Engineering Department, King Fahd University of Petroleum and Minerals, Dhahran, Saudi Arabia
³3Interdisciplinary Research Center for Intelligent Manufacturing and Robotics, KFUPM, Dhahran, Saudi Arabia

Keywords: finite element method, cutting simulation, tool inserts, performance.

Abstract

A computational material design approach is used to design a novel ceramic material with improved thermal and structural performance for cutting tool inserts. Many competing requirements are inherent in material design, necessitating careful consideration of critical considerations in terms of material phase composition, reinforcement size, morphology, and distribution in order to attain the intended properties. When compared to commercial stand-alone alumina (Al2O3), the hybrid alumina/silicon carbide/cubic boron nitride composite (Al2O3/SiC/cBN) employed for cutting inserts is found to be the suited design among other alternatives with enhanced thermal and structural properties. In order to study the performance characteristics and the effects of the new ceramic composite with improved properties, a fully coupled thermal and structural analysis of the cutting tool insert during cutting of high strength steel alloy is evaluated using finite element method and compared with Al2O3 inserts. Stress distribution and temperature profile are observed as a function of time during dry cutting conditions. Improved thermal performance of a cutting insert made of Al2O3/SiC/cBN is found due to better resistance to thermal shock which can be associated with better flow of temperature through the insert. The stresses generated due to the combined effect of the heat flux and mechanical loading on the cutting edge are analyzed and it is found that the newly proposed hybrid composite is a potential substitute for commercially available ceramic inserts.

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Front Page Browse CCC CCP CSETS CTR IJRT Other Authors Search Purchase Guide FAQ Contact us	Civil-Comp Conferences ISSN 2753-3239 CCC: 2 PROCEEDINGS OF THE ELEVENTH INTERNATIONAL CONFERENCE ON ENGINEERING COMPUTATIONAL TECHNOLOGY Edited by: B.H.V. Topping and P. Iványi Paper 5.3 Simulation led Performance Evaluation of a Hybrid Al2O3/SiC/cBN Composites for Cutting Tool Inserts T. Waqar¹ and S.S. Akhtar^2,3 ¹Department of Mechanical Engineering, University of British Columbia, Okanagan, BC, Canada ²Mechanical Engineering Department, King Fahd University of Petroleum and Minerals, Dhahran, Saudi Arabia ³3Interdisciplinary Research Center for Intelligent Manufacturing and Robotics, KFUPM, Dhahran, Saudi Arabia doi:10.4203/ccc.2.5.3 Full Bibliographic Reference for this paper T. Waqar, S.S. Akhtar, "Simulation led Performance Evaluation of a Hybrid Al2O3/SiC/cBN Composites for Cutting Tool Inserts", in B.H.V. Topping, P. Iványi, (Editors), "Proceedings of the Eleventh International Conference on Engineering Computational Technology", Civil-Comp Press, Edinburgh, UK, Online volume: CCC 2, Paper 5.3, 2022, doi:10.4203/ccc.2.5.3 Keywords: finite element method, cutting simulation, tool inserts, performance. Abstract A computational material design approach is used to design a novel ceramic material with improved thermal and structural performance for cutting tool inserts. Many competing requirements are inherent in material design, necessitating careful consideration of critical considerations in terms of material phase composition, reinforcement size, morphology, and distribution in order to attain the intended properties. When compared to commercial stand-alone alumina (Al2O3), the hybrid alumina/silicon carbide/cubic boron nitride composite (Al2O3/SiC/cBN) employed for cutting inserts is found to be the suited design among other alternatives with enhanced thermal and structural properties. In order to study the performance characteristics and the effects of the new ceramic composite with improved properties, a fully coupled thermal and structural analysis of the cutting tool insert during cutting of high strength steel alloy is evaluated using finite element method and compared with Al2O3 inserts. Stress distribution and temperature profile are observed as a function of time during dry cutting conditions. Improved thermal performance of a cutting insert made of Al2O3/SiC/cBN is found due to better resistance to thermal shock which can be associated with better flow of temperature through the insert. The stresses generated due to the combined effect of the heat flux and mechanical loading on the cutting edge are analyzed and it is found that the newly proposed hybrid composite is a potential substitute for commercially available ceramic inserts. download the full-text of this paper (PDF, 8 pages, 358 Kb) go to the previous paper go to the next paper return to the table of contents return to the volume description
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