Abstract:
Double tool turning process is used to improve productivity. A 2D finite element model was
developed using commercially available finite element analysis software Abaqus 6.13. The workpiece and
the cutting tool materials are modelled as elasto-plastic and elastic material respectively. Johnson-Cook
damage criterion was used for chip separation. The friction between the cutting tool and the workpiece is
modelled based on penalty contact approach. The coefficient of friction between the chip and the first and
second cutting tool was taken as 0.8 and 0.6 respectively. In this numerical investigation the effect tool
separation distance over the cutting force, feed force and cutting temperature were studied. Three different
tool separation distances were considered. The simulation result shows that cutting force and feed force of
the front cutting tool and the rear cutting tool do not change appreciably with the variation of the tool
separation distance. It was revealed that the temperature rise of the work material due to machining by two
cutting tool is well below the recrystallization temperature. Hence the forces on front and rear cutting tool
remain same for various tool separation distances. It was also observed that the cutting temperatures
remained unchanged for the various tool separation distances.
