Analysis of Thermal Aspect in Hard Turning of AISI 52100 Alloy Steel Under Minimal Cutting Fluid Environment Using FEM
This paper describes a simulation study on the hard turning of AISI 52100 alloy steel with coated carbide tools under minimal cutting fluid conditions using the commercial software AdvantEdge. A finite element analysis coupled with adaptive meshing was carried out to accurately capture temperature g...
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2025-03-01
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| author | Sandip Mane Rajkumar Bhimgonda Patil Mohan Lal Kolhe Anindita Roy Amol Gulabrao Kamble Amit Chaudhari |
| author_facet | Sandip Mane Rajkumar Bhimgonda Patil Mohan Lal Kolhe Anindita Roy Amol Gulabrao Kamble Amit Chaudhari |
| author_sort | Sandip Mane |
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| description | This paper describes a simulation study on the hard turning of AISI 52100 alloy steel with coated carbide tools under minimal cutting fluid conditions using the commercial software AdvantEdge. A finite element analysis coupled with adaptive meshing was carried out to accurately capture temperature gradients. To minimise the number of experiments while optimising the cutting parameters along with fluid application parameters, a cutting speed (v) of 80 m/min, feed rate (f) of 0.05 mm/rev, depth of cut (d) of 0.15 mm, nozzle stand-off distance (NSD) of 20 mm, jet angle (JA) of 30°, and jet velocity (JV) of 50 m/s were observed to be the optimal process parameters based on the combined response’s signal-to-noise ratios. The effects of each parameter on machined surface temperature, cutting force, cutting temperature, and tool–chip contact length were determined using ANOVA. The depth of cut affected cutting force, while cutting speed and jet velocity affected cutting temperature and tool–chip contact length. Cutting speed influenced machined surface temperature significantly, whereas other parameters showed minimal effect. Nozzle stand-off distance exhibited less significant effect. Taguchi optimisation determined the optimal combination of process parameters for minimising thermal effects during hard turning. Cutting temperature and cutting force simulation results were found to be highly consistent with experimental results. On the other hand, the simulated results for the tool–chip contact length and machined surface temperature were very close to the values found in the literature. The result validated the finite element model’s ability to accurately simulate thermal behaviour during hard-turning operations. |
| format | Article |
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| institution | Kabale University |
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| publishDate | 2025-03-01 |
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| series | Applied Mechanics |
| spelling | doaj-art-e5003e5432c042e993f3e9b95dec8cd62025-08-20T03:27:26ZengMDPI AGApplied Mechanics2673-31612025-03-01622610.3390/applmech6020026Analysis of Thermal Aspect in Hard Turning of AISI 52100 Alloy Steel Under Minimal Cutting Fluid Environment Using FEMSandip Mane0Rajkumar Bhimgonda Patil1Mohan Lal Kolhe2Anindita Roy3Amol Gulabrao Kamble4Amit Chaudhari5Department of Mechanical Engineering, Dwarkadas J. Sanghvi Engineering College, Mumbai 400056, Maharashtra, IndiaDepartment of Mechanical Engineering, Dwarkadas J. Sanghvi Engineering College, Mumbai 400056, Maharashtra, IndiaFaculty of Engineering & Science, University of Agder, 4604 Kristiansand, NorwaySymbiosis Institute of Technology, Symbiosis International (Deemed) University, Pune 412115, Maharashtra, IndiaMechanical Engineering, Amity University Maharashtra, Mumbai, Raigad 410206, Maharashtra, IndiaDepartment of Mechanical Engineering, Dwarkadas J. Sanghvi Engineering College, Mumbai 400056, Maharashtra, IndiaThis paper describes a simulation study on the hard turning of AISI 52100 alloy steel with coated carbide tools under minimal cutting fluid conditions using the commercial software AdvantEdge. A finite element analysis coupled with adaptive meshing was carried out to accurately capture temperature gradients. To minimise the number of experiments while optimising the cutting parameters along with fluid application parameters, a cutting speed (v) of 80 m/min, feed rate (f) of 0.05 mm/rev, depth of cut (d) of 0.15 mm, nozzle stand-off distance (NSD) of 20 mm, jet angle (JA) of 30°, and jet velocity (JV) of 50 m/s were observed to be the optimal process parameters based on the combined response’s signal-to-noise ratios. The effects of each parameter on machined surface temperature, cutting force, cutting temperature, and tool–chip contact length were determined using ANOVA. The depth of cut affected cutting force, while cutting speed and jet velocity affected cutting temperature and tool–chip contact length. Cutting speed influenced machined surface temperature significantly, whereas other parameters showed minimal effect. Nozzle stand-off distance exhibited less significant effect. Taguchi optimisation determined the optimal combination of process parameters for minimising thermal effects during hard turning. Cutting temperature and cutting force simulation results were found to be highly consistent with experimental results. On the other hand, the simulated results for the tool–chip contact length and machined surface temperature were very close to the values found in the literature. The result validated the finite element model’s ability to accurately simulate thermal behaviour during hard-turning operations.https://www.mdpi.com/2673-3161/6/2/26hard turningfinite element analysisdesign of experimentsanalysis of variancecutting forcecutting temperature |
| spellingShingle | Sandip Mane Rajkumar Bhimgonda Patil Mohan Lal Kolhe Anindita Roy Amol Gulabrao Kamble Amit Chaudhari Analysis of Thermal Aspect in Hard Turning of AISI 52100 Alloy Steel Under Minimal Cutting Fluid Environment Using FEM Applied Mechanics hard turning finite element analysis design of experiments analysis of variance cutting force cutting temperature |
| title | Analysis of Thermal Aspect in Hard Turning of AISI 52100 Alloy Steel Under Minimal Cutting Fluid Environment Using FEM |
| title_full | Analysis of Thermal Aspect in Hard Turning of AISI 52100 Alloy Steel Under Minimal Cutting Fluid Environment Using FEM |
| title_fullStr | Analysis of Thermal Aspect in Hard Turning of AISI 52100 Alloy Steel Under Minimal Cutting Fluid Environment Using FEM |
| title_full_unstemmed | Analysis of Thermal Aspect in Hard Turning of AISI 52100 Alloy Steel Under Minimal Cutting Fluid Environment Using FEM |
| title_short | Analysis of Thermal Aspect in Hard Turning of AISI 52100 Alloy Steel Under Minimal Cutting Fluid Environment Using FEM |
| title_sort | analysis of thermal aspect in hard turning of aisi 52100 alloy steel under minimal cutting fluid environment using fem |
| topic | hard turning finite element analysis design of experiments analysis of variance cutting force cutting temperature |
| url | https://www.mdpi.com/2673-3161/6/2/26 |
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