Investigation of tool wear patterns and their optimization in single point cutting tool
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The main tasks to be elaborated in this thesis are four: The first task is an overview of the theoretical background on different tool wear patterns, this task is mainly divided into two parts. I used different bibliographies to review the existing literature to find out what recent researches say about these wear patterns, I explained and developed different tool wear patterns, their causes, and the possible methods to minimize or avoid them from happening. The second task is about creating a 3D model of the cutting tool deformation during machining. In this section, I used Solidworks software to create a 3D model of a single-point cutting tool and a cylindrical workpiece. Both models have been joined by the assembly method to facilitate the simulation as an entity-body import. The Third task is about carrying out Finite Element Analysis for the tool Pattern. I used ANSYS 2023 R1 software during this analysis. I used the Explicit Dynamics in Ansys at different depths of cut of 0.5 mm, 1mm, 1.5mm, and 2mm and the federate of 0.1, 0.2, 0.3, 0.4, and 0.5 mm/sec. The material used for the workpiece is structural steel and high-speed steel for a single-point cutting tool. After making the simulation, the final results have been evaluated. The deformation, the equivalent (Von-Mises) stress, and the reaction force have been generated. The fourth task concerns the evaluation of the results and comparison with scientific research resources. Based on the results on stress, deformation and the reaction forces found, a comparison was made and it has been found that by increasing the depth of cut and federate, the cutting force (reactive) increases and this is the major cause of the cutting tool wear.