سيداميرحسين احمدي

Surface quality plays a significant role in determining the performance of a component, as a considerable portion of component failures originates from the surface. Surface roughness is an important parameter in describing a surface, and in manufacturing industries, a surface must fall within a specific range of roughness. Therefore, assessing surface roughness is crucial for quality control in workpiece machining. One of the objectives of this research is to examine the effect of certain input parameters, including dry and cryogenic machining environments, as well as three levels of cutting speed, feed rate, and tool nose radius, on surface quality characteristics during the machining of AISI 420 stainless steel. In this regard, a two-dimensional simulation was initially developed, and based on its key insights, a more extensive three-dimensional model was created, which revealed issues related to data storage size and processing costs. To resolve these issues, a three-dimensional finite element method (FEM) simulation was further developed and optimized based on the geometry of the turning operation using ABAQUS/CAE 2021 software. After presenting and analyzing the numerical and experimental data, the results of the numerical simulation were validated and eva‎luated using data from experimental tests. Despite the occurrence of chatter in some experimental tests, it was found that using the developed models in this study, the surface roughness of the machined surfaces in the remaining tests was simulated with an accuracy of less than 1 micrometer. Furthermore, through ANOVA statistical analysis, the effect of some cutting parameters on machining output, including certain commonly used surface quality characteristics, was examined. The results from these simulations eva‎luated the trends of the examined parameters' effects on surface roughness in accordance with the trends observed in experimental machining. Accordingly, the numerical and experimental results demonstrated the significant impact of increased feed rate on raising surface roughness, as well as the effects of increased cutting speed and tool nose radius on reducing surface roughness.

شبيه سازي عددي , تراشكاري AISI 420 , كيفيت سطح , ماشينكاري خشك , ماشينكاري برودتي

Numerical simulation , Turning of AISI 420 , Surface quality , Dry machining , Cryogenic machining

Seyed Amirhossein Ahmadi

Dr. Behnam Davoodi - Dr. Seyed Ali Niknam