Numerical and Statistical Model to Determine Temperature and Heat Distribution When Machining HASTELLOY C-22HS

Abstract

The aim of this study is to determine temperature and heat distribution when machining HASTELLOY C-22HS with carbide coated cutting tool using finite element analysis and response surface method. The simulation is divided into two stages; in the first stage the simulation is run without coolant and in the second stage the simulation is run with coolant model. The contour plots are used to show the distributions of parameters in the deformation zone. Response surface method (RSM) is used to minimize the number of experiments that is need to simulate and developed temperature and heat first order model. This model shows clearly the relationship between variables (cutting speed, feedrate and axial depth) with responses (temperature and heat generation). From the numerical results, it shows that the coolant plays major role in reducing the temperature and heat at the tool tip and the sliding area between chip and cutting tool. The maximum temperatures for relatively smaller cutting speeds occur at the half of the contact length from cutting edge. It moves through the two-third of the contact length for higher cutting speeds. The trend of distribution of both parameters have been compared with others work. The first order model, shows that cutting speed, feedrate and axial depth plays important role in producing cutting temperature and heat.