Proc.

of Int. Conf. on
Computing, Communication & Manufacturing 2014

Stress Analysis Criteria of High Speed Steel Single

Point Turning Tool
Mr. Soutrik Bose1, Mr. Tapishnu Samanta2, Mr. Amritabha Chakraborty3

1,2,3

Mechanical Engineering Department, MCKV Institute of Engineering, 243 G.T. Road (N), Liluah, Howrah 711204
Email: 1soutrikboseju@gmail.com, 2samanta.tapishnu@gmail.com, 3amritabha.cha@gmail.com
Abstract High speed steel (HSS) is a material usually used in the manufacture of machine
tool bits and other cutters. In this paper, certain tool geometry (6-8-10-10-20-45-0.6) is taken
and a cutting tool is been made by considering other parameters. Accordingly a 3d model of the
tool is been made in finite element software package ANSYS-10. The model is used to
investigate the effective and shear stresses on the HSS tool. Detailed results of the cutting forces
generated during the machining process are presented and a comparison has been made with
the experimental results for a range of feeds. The final goal of the system is the generation of
cutting forces and then the von Mises equivalent stress contours are generated in ANSYS after
importing the tool model in parasolid format from solidworks and after applying cutting forces
to the centre of pressure region. Solution is done keeping displacement fixed to 0 at the side of
the dynamometer. Free meshing is done in this 10 noded element tool. The vulnerable region of
the tool is identified by von misses stresses.
Index Terms Machining, Cutting forces, Solidworks, Stress Analysis.

I.

INTRODUCTION

An increase in productivity requires involvement of all production operations, technical possibility for full
use or activation of all the available manufacturing facilities. In order to involve all the technological operations,
optimum technological processes, optimum tool selection, suitable combination of tool-workpiece material and
determination of optimum cutting variables and tool geometry must be considered [1-4]. The tool geometry has
an important factor on cutting forces and cutting forces are essential sources of information about productive
machining. The amplitude and frequency of cutting forces and torque are used in sizing machine tool structures,
spindle and feed drive mechanisms, calculating the required power as well optimal planning of individual
machining operations based on physical constraints [4,5]. During cutting process, the cutting tool penetrates into
the workpiece due to the relative motion between tool and workpiece. The cutting forces are measured by the
dynamometers designed for different working principles on a measuring plane in the Cartesian coordinate system
[2-4]. The cutting process is defined as being a stochastically stationary process so that its prediction cannot be
made on the basis of its theoretical analysis. Because the cutting force is known to be very sensitive to even the
smallest changes in the cutting process, the attentions were directed to the selection of the conditions of the tests
and experimental methodology. Measuring the cutting forces involves three successive stages: pre-process,
measuring, and analysis and evaluation of the test results. Therefore, instead of calculating the cutting force
theoretically, measuring them in process by dynamometers is preferred. The experiments are carried out on lathe
machine and cutting force components are measured in process. Finally, the stress contours are found in ANSYS
and vulnerable region is identified [6,7].
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II. METHODOLOGY
A. Experimental set-up
The experimental set-up (Fig. 1a) was prepared by using cutting parameters and test conditions that are
advised for a couple of tool-workpiece by the tool manufacturer. In order to measure cutting forces (main cutting
force Fc, feed force Ff, and thrust force Ft), a 2d turning dynamometer was used. Although most of the heat
generated in the cutting process is taken away by the chip (nearly 80% of total heat [3,4]) from the cutting zone,
the important rate of the heat is passed into the tool. Thus, measuring the temperature on crater zone of the tool is
a good indicator about the total heat generated. For further evaluation, the force signals and temperature signals
obtained are transferred to PC by means of the data acquisition card.
B. Test material
Workpiece material is taken to be of mild steel bar of 0.6 metre in length and 100 mm. in diameter. After
taking the readings of the cutting forces the diameter decreases and noted accordingly for variable cutting
velocity.
C. Cutting tool and cutting parameters
The cutting tests were carried in single-point turning operations. Three process parameters namely feed rate,
cutting speed and depth of cut were considered to perform turning operations keeping all other parameters
constant. Experiments were carried out according to the parameter settings shown in Table 1 (Fig 1b). The tests
were designed according to full factorial design and conducted in dry cutting conditions. Totally, 15 cutting
forces were analyzed by the combinations of cutting parameters. The cutting forces are shown in Fig. 1a.

Fig. 1 (a) Experimental Set-up & Diagram of cutting forces

Fig. 1 (b). Cutting parameters.

III. EXPERIMENTAL APPROACH

Experimentally cutting forces are analyzed by monitoring by the data acquisition card through dynamometer
and oscilloscope by maintaining a fixed spindle speed and keeping the other parameters constant; depth of cut
and feedrate and then vary accordingly. These forces once generated are given to the 3d model of the cutting tool
designed in ANSYS-10 and the stress, strain and displacement contours are found accordingly. The vulnerable
region of the cutting tool is identified based on the tensile and compressive stresses obtained through analysis.
An idealized tool which would not break at high speed cutting conditions may be designed by decreasing the
tensile stress generated at the nose region of the tool.
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IV. MEASURING OF CUTTING FORCES

Cutting forces are measured by varying different parameters like feedrate, depth of cut and spindle speed like
f = 0.08382, 0.508 mm/rev. n = 145 rpm. d = 0.127, 0.254, 0.381 mm. Cutting forces are measured in picoscope
and shown in Table 1.
Table 1. Cutting forces by varying the parameters.

46.976
46.687
46.455

Tangential
cutting force
Fz
(N)
60.3876
71.0442
86.4372

Axial
cutting force
Fx
(N)
10.5
16.4
18.9

46.252
45.963

358.2832
352.0991

152.6
145.93

Feed f
(mm/rev)

Spindle
speed n
(rpm)

Depth of cut
d (mm)

Cutting
velocity v
(m/min)

0.08382

145

0.127
0.254
0.381

0.508

145

0.127
0.254

Radial cutting
force Fy
(N)
8.4543
9.9462
12.1012
50.16
49.29

The radial cutting force (Fy) is not detected by the dynamometer as it a 2d strain gauge dynamometer. The
radial cutting force is dependent on tangential cutting force and it is calculated by the formula below [4]
Fy = 0.14*Fz
V. RESULT AND DISCUSSION
A. Finite Element Method
A cutting tool is usually subjected to multi-axial stresses in a cutting process such that each face may be
subjected to the total force. Relatively lower tensile strength of modern cutting tools (i.e., carbide tools) makes
them prone to brittle failure due to chipping and fracture. Premature failure often results due to improper
selection of cutting parameters, which causes excessive stress on the cutting edge. Generally when the induced
stress in a cutting tool reaches a critical value, tool failure will occur. In cutting process, the surface is influenced
by changes in tool geometry, chip flow, temperature generation, heat flow and tool wears. The understanding of
these interactions during the cutting process is done by static and dynamic analyses with the help of finite
element analysis software, called ANSYS [6,7].
A.1. Static analysis
A static analysis calculates the effects of steady loading conditions on a structure, while ignoring inertia and
damping effects. It has been assumed that the orthogonal machining process is in steady-state, a continuous chip
is produced and the workpiece material is elasticviscoplastic. In a static analysis a rigidity matrix is calculated
for each element according to the given specifications. These matrices are aggregated and the rigidity matrix of
the system is generated. The solution is the zero displacements of the nodes that are fixed to the tool holder. In
this research, free meshes are used for the FEM of the cutting tool. The adopted mesh is an arrangement of solid
10 noded elements. Experimental data shows that if the calculated stress of the cutting tool is much above the
material yield strength, the tool fractures under the critical forces. Since these forces are the measured forces
when the tool breaks, the result shows that the metal cutting process predicted by the finite elements model
agreed well with experimental results [6,7].
A.2. Dynamic analysis
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The dynamic analysis represents that the actual cutting forces also depends on various other factors like
natural frequency of the lathe, unusual noise and disturbance due to eccentricity of loading conditions, excessive
cutting velocity, etc. Since only linear behaviour is valid in this analysis, any non-linearity is ignored even if they
are defined. For this reason, the cutting tool structure defined in this work is assumed to have linear behaviour.
B. Finite Element Modelling
B.1. Steady state orthogonal machining
The cutting tool is modelled with a nose radius of 0.6 mm. The tool geometry is 6-8-10-10-20-45-0.6 (Table
2). The initial tool geometry was drawn in Solid works and imported into ANSYS in parasolid format. In order to
compare the finite element analysis results to those obtained experimentally the following approach was used.
The workpiece was assumed to be elasto-viscoplastic whilst the tool was assumed to be elastic. The spindle
speed used for the simulations was 145 rpm, feedrate 0.08382, 0.508 mm/rev, and depth of cut 0.127, 0.254,
0.381 mm to experimental conditions. Material properties given in Table 3.
Table 2. Secondary input parameters.
Inclination
angle
6o

Top rake
angle
8o

Side relief
angle
10o

End relief
angle
10o

Auxiliary cutting
edge angle
20o

Approach
angle
45o

Nose
radius
0.6 mm

Table 3. Material properties of the tool.

Tool

Density (g/cc)

HSS

7.72

Youngs
Modulus(GPa)
190

Poissons
Ratio
0.27

Thermal
Expansion/k
9.4*10^-6

Yield
(MPa)
380

Strength

B.2. Stress analysis of the cutting tool

During the orthogonal machining with the tool, the chip is formed by shearing in the primary deformation
zone. As a result of very high shear stresses and pressures at the chiptool interface, a secondary deformation
zone along the chiptool interface also occurs. The magnitude of the von Mises equivalent stress increases while
the workpiece element goes through the primary deformation zone. However, with the irregular-shaped particles
employed in this work, extremely high local stresses are developed at the particle corners. Particle clustering also
leads to an increase in the stress on and around the hard particles. The equivalent von Mises stress on the hard
particle was found to have the highest value in the primary deformation zone which is due to the high
compressive stress exerted by the cutting tool tip. The result obtained from the experiment has been shown in
Table 4. Several input parameters were chosen by sampling and a few of the stress analyses done on ANSYS are
shown below:

303

Fig 2. von Mises stress when f = 0.08382mm/rev, n =

145 rpm, d = 0.127mm

Fig 3. von Mises stress when f = 0.08382mm/rev, n =

145 rpm, d = 0.254mm

Fig 4. von Mises stress when f = 0.508mm/rev, n = Fig 5. von Mises stress when f = 0.508mm/rev, n =
145rpm, d=0.127mm
145rpm, d = 0.254mm
Table 4. von Mises maximum and minimum stresses along with the cutting forces.
Tangenti
Axial
Max von
Min von
Spindle Depth
Cutting
al
Radial
Feed f
cutting
Mises
Mises
speed
of cut
velocity
cutting
cutting
(mm/re
force
Stress
Stress
n
d
v
force
force Fy
v)
Fx
(MPa)
(Pa)
(rpm)
(mm)
(m/min)
Fz
(N)
(N)
(N)
0.127
46.976
60.3876
10.5
8.4543
9.95
377.176
0.08382 145
0.254
46.687
71.0442
16.4
9.9462
14.6
603.273
0.381
46.455
86.4372
18.9
12.1012
3.51
674.259
358.283
0.127
46.252
2
152.6
50.16
298
4919
0.508
145
0.254
45.963
352.099
145.93
49.29
590
23258
1
The results of the finite element modelling indicate that the orthogonal machining process with continuous
chip formation can indeed be modelled with ANSYS 10. However the error between the finite element results
and the experimental test results can be explained in a number of ways. Initially the tool is said to be stress free.
That is, no residual stresses arise from the mismatch of the coefficients of thermal expansions for the different
materials. Consequently it is important to know the direct and shear stresses between the tool and workpiece. It
was also found that the thickness and cutting forces at centre of pressure influenced the stresses at the various
nodes. The value of the tangential stress at the surface has a significant influence on the working life of the tool
component. If this tangential stress is highly compressive, it can lead to buckling, and if tensile, it can lead to
built up edge (BUE) and breakage resulting in tool fracture. So the magnitude of the tangential stress should be
decreased with increasing distance below the outer surface of the tool. However due to the stiffness of the
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substrate, the maximum von Mises stress is measured. The tool geometry is checked with tool makers
microscope.
The following graphs show how the three cutting forces and von Mises maximum stress are related with the
cutting velocity when the other parameters like feedrates, spindle speeds and depth of cuts are varied.
FEED=0.08382mm/rev,n=145rpm

FEED = 0.08382mm/rev , n = 145 rpm

47.1

47.1
tan force
axial force
radial force

(m/min)

47

46.9

CUTTING VELOCITY

CUTTING VELOCITY (m/min)

47

46.8

46.7

46.6

46.9

46.8

46.7

46.6

46.5

46.5
2

10

20

30
40
50
60
CUTTING FORCES (N)

70

80

90

Fig 6. Cutting forces vs. cutting velocity at f = 0.08382

mm/rev, n = 145 rpm.

14

16

FEED=0.508mm/rev,n=145rpm

FEED=0.508mm/rev,n=145rpm
46.35

tan force
axial force
radial force

46.3

CUTTING VELOCITY (m/min)

46.3

CUTTING VELOCITY (m/min)

12
(MPa)

Fig 7. Max von Mises stress vs. cutting velocity at f

= 0.08382 mm/rev, n = 145 rpm.

46.35

46.25
46.2
46.15
46.1
46.05

46.25
46.2
46.15
46.1
46.05
46

46
45.95

6
8
10
MAX VON MISES STRESS

45.95
250

50

100

150
200
250
CUTTING FORCES
(N)

300

350

400

Fig 8. Cutting forces vs. cutting velocity at f = 0.508

mm/rev, n = 145 rpm.

300

350
400
450
MAX VON MISES STRESS

500
(MPa)

550

600

Fig 9. Max von Mises stress vs. cutting velocity at f

= 0.508 mm/rev, n = 145 rpm.

VI. CONCLUSION
In the course of this study we have found the cutting forces by a 2d strain gauge dynamometer and strain
indicator. On the other hand the effects of cutting forces to that spindle speed, feed rate, depth of cut and cutting
velocity are observed. It can be concluded from the study that the cutting forces are directly proportional to feed,
spindle speed and depth of cut and inversely proportional to the cutting velocity. The von Mises equivalent stress
is also directly proportional to feed, depth of cut but inversely proportional to cutting velocity. The vulnerable
region is identified from the stress contours. It is also observed that the von Mises equivalent stress is 590 MPa
which is much higher than the yield strength 380 MPa resulting in tool wear.
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