ISSN 2393-8471

International Journal of Recent Research in Civil and Mechanical Engineering (IJRRCME)

Vol. 5, Issue 2, pp: (7-12), Month: October 2018 – March 2019, Available at: www.paperpublications.org

Single Point Cutting Tool and Its Thermal

Analysis
B Nagu Naik1, Y. Raj Kumar2, T. Aravind3
1,2
Department of Mechanical Engineering, Sri Indu College of Engineering and Technology, Hyderabad

Abstract: Single point cutting tool is standard tool used for various machining operations. Work is done to find
temperature at tool chip interface at various speeds with thermal analysis. The different analyses are done to
compare with experimental analysis at low speed, medium and high speeds. These three different analyses are
done on High Speed Steel and of a Carbide Tip Tool machining process at three different cutting speeds, in order
to compare to experimental results produced as part of this study. Heat generation analysis is done by varying the
geometrical parameters of tool. Investigators made attempt to measure these cutting temperatures with various
techniques during machining. Single point cutting tool has been solid modelled by using SOLIDWORKS 2013 and
Finite Element Analysis carried out by using ANSYS Workbench 15. By varying various parameters the effect of
those on temperature are compared with the experimental results and FEA results.
Keywords: Single Point Cutting Tool, HSS tool and Carbide tip tool, Centre lathe, Fluke IR Thermal Imager, Finite
Element Analysis, Solid Modelling.

I. INTRODUCTION
A large amount of heat is generated during machining process as well as in different process where deformation of
material occurs. The temperature that is generated at the surface of cutting tool when cutting tool comes in contact with
the work piece is termed as cutting tool temperature. Heat is a parameter which strongly influences the tool performance
during the operation. We know the power consumed in metal cutting is largely converted into heat. Temperature being
developed during cutting it is of much concern as a result heat are mainly dependent on the contact between the tool and
chip, the amount of cutting force and the friction between the tool and chip. Almost all the heat energy produced is
transferred into the cutting tool and work piece material while a potion is dissipated through the chip. During machining
the deformation process is highly concentrated in a very small zone and the temperatures generated in the deformation
zone affect both the work piece and tool. Tool wear, tool life, work piece surface integrity, chip formation mechanism are
strongly influenced at high cutting temperatures and contribute to the thermal deformation of the cutting tool, which is
considered as the largest source of error in the machining process. There has been a considerable amount of research
devoted to develop analytical and numeric models in order to simulate metal cutting processes to predict the effects of
machining variable such as speed, feed, depth of cut and also tool geometry on deformations of tool. Especially,
numerical models are highly essential in predicting chip formation, computing forces, distributions of strain, strain rate,
temperatures and stresses on the cutting edge and the machined work surface. Advanced process simulation techniques
are necessary in order to study the influence of the tool edge geometry and cutting conditions on the surface integrity
especially on the machining induced stresses. The objective is to analyze the temperature distribution on a tool of different
materials at various machining parameters using analysis software ANSYS.

II. CONCEPT OF HEAT GENERATION IN SINGLE POINT CUTTING TOOL

In machining of metal with single point cutting tool, the heat is generated due to the friction between chip produced and
the tool. At the same time, at the zone of metal separation and cutting edge also the heat is generated. Hence, the heat is
generated in three zones as shown in Figure 1.
Page | 7
Paper Publications
 ISSN 2393-8471

International Journal of Recent Research in Civil and Mechanical Engineering (IJRRCME)

Vol. 5, Issue 2, pp: (7-12), Month: October 2018 – March 2019, Available at: www.paperpublications.org

Fig. 1

In shear zone, maximum heat is generated because of the plastic deformation of metal, and practically all of this heat is
carried away by the chip as machining is rapid and continuous process. Avery minor portion of this heat (5-10%) is
conducted to work piece. In friction zone, the heat is generated mainly due to friction between moving chip and tool face
and partly due to secondary deformation of the built up edge. In work-tool contact zone, the heat is generated due to
burnishing friction and the heat in this zone goes on increasing with time as the wear land on the tool develops and goes
on increasing. It will be noted that each of these three zones leads to rise of temperature at the tool chip interface and it is
found that the maximum temperature occurs slightly away from the cutting edge, and not at the cutting edge.

III. MODELLING OF SINGLE POINT CUTTING TOOL

The single point cutting tool has been solid modelled by using SOLIDWORKS, a solid modelling computer aided design
software. Solidworks is a solid modeller, and utilizes parametric feature-based approach to create models and assemblies.
Parameters refer to constraints whose values determine the shape of or geometry of the model or assembly. Parameters
can be either numeric parameter, such as tangent, parallel, concentric, horizontal or vertical etc. numeric parameters can
be associated with each other through the use of relations.
The main dimensions of the tool and work piece is summarized below in Table 1.
Table 1: Main dimensions of the tool and work piece

Cutting Tool Work piece

Material High Speed Steel Mild Steel

Tungsten carbide
Cross-section 12*100.9 mm

Side and end cutting edge angles: 30° End Ø22.5*62.8 mm

relief angle: 20°
Solidworks is used for 3D modelling of single point cutting tool. 3D views are given below for reference. Various
commands are used like sketch, line, extrude, cut extrude etc.

Fig. 2

The end part of the main body is made with the help of commands like sketch, pad. The sketching is on a defined plane as
line diagram and it is solid extruded with the help of pad command. With the help of fillet and pad command in CATIA,
the final Rocker arm is made.
Page | 8
Paper Publications
 ISSN 2393-8471

International Journal of Recent Research in Civil and Mechanical Engineering (IJRRCME)

Vol. 5, Issue 2, pp: (7-12), Month: October 2018 – March 2019, Available at: www.paperpublications.org

IV. FINITE ELEMENT ANALYSIS OF SINGLE POINT CUTTING TOOL

The 3D modelled cutting tool is inserted into the ANSYS WORKBENCH. The following figure shows the inserted 3D
modelled tool into the ANSYS WORKBENCH. The cutting material is used as T15 High Speed Steel. The Temperature
dependent properties are summarised in a table which is followed by the below figure.
Coefficient of thermal expansion: 1.01*10-5 °C-1 (Ref temp: 22 °C) Young‟s modulus: 2.07*105 Mpa

Fig. 3

Table 2: Properties of T15 super high speed steel

Sl No Temperature (°C) Density (kg/m3) Thermal Conductivity(w/mK) Specific Heat(J/kgK)

1 0 8190 19 418.68
2 50 8186 20 420
3 75 8183 22 425.36
4 100 8179 23 430.45
5 120 8177 25 436.25
6 175 8172 26 442.57
7 200 8168 28 445.68
8 220 8162 30 448.35

Poisson‟s ratio: 0.25

The work piece material used is mild steel. The various properties of mild steel are given below,
Density: 7850 kg/m3
Coefficient of thermal expansion: 1.2*10-5 °C-1 (Ref temp:20 °C) Young‟s modulus: 2*1011 Pa
Poisson‟s ratio: 0.3
Thermal conductivity: 60.5 w/mK Specific heat: 434 J/kgK
Next step is, An APDL command is used to change element type. Element must be chosen accordingly to mesh geometry.
Here „Brick 20 node SOLID 226‟ is used as work piece element and „Tetra 10 node SOLID227‟ is used as cutting tool
element.
The SOLID226 element has twenty nodes with up to five degrees of freedom per node. Structural capabilities include
elasticity, plasticity, viscoelasticity, viscoplasticity, creep, large strain, large deflection, stress stiffening effects, and
prestress effects. Thermoelectric capabilities include Seebeck, Peltier, and Thomson effects, as well as Joule heating. In
addition to thermal expansion, structural-thermal capabilities include the piezocaloric effect in dynamic analyses. The
Coriolis Effect is available for analyses with structural degrees of freedom. The thermoplastic effect is available for
analyses with structural and thermal degrees of freedom. The diffusion expansion effect is available for analyses with
structural and diffusion degrees of freedom.

Page | 9
Paper Publications
 ISSN 2393-8471

International Journal of Recent Research in Civil and Mechanical Engineering (IJRRCME)

Vol. 5, Issue 2, pp: (7-12), Month: October 2018 – March 2019, Available at: www.paperpublications.org

The SOLID227 element has twenty nodes with up to five degrees of freedom per node. Structural capabilities include
elasticity, plasticity, viscoelasticity, viscoplasticity, creep, large strain, large deflection, stress stiffening effects, and
prestress effects. Thermoelectric capabilities include Seebeck, Peltier, and Thomson effects, as well as Joule heating. In
addition to thermal expansion, structural-thermal capabilities include the piezocaloric effect in dynamic analyses. The
Coriolis Effect is available for analyses with structural degrees of freedom. The thermoplastic effect is available for
analyses with structural and thermal degrees of freedom. The diffusion expansion effect is available for analyses with
structural and diffusion degrees of freedom.
The APDL command used for changing the element type is given below.
ET, matid, SOLID 226: This changes element type to SOLID226. KEYOPT, mat id, 1, 11: This defines Thermal-
Structural behaviour. ET, matid, SOLID227: This changes element type to SOLID227.
KEYOPT, mat id, 1, 11: This defines Thermal-Structural behaviour.
The method used for meshing the cutting tool is „Hex dominant method “giving a body sizing of 1.5 mm and for work
piece is „Multi zone method‟ giving a body sizing of 2.5 mm. The meshed geometry is given in Figure 4.

Fig. 4

Load and Boundary Conditions Structural loads and boundary conditions are applied as usual. Here we have four
conditions.
1. Cylindrical support for work piece
2. Longitudinal displacement of tool
3. Tangential displacement of tool (0.1 mm, 0.4 mm, 0.7 mm) 4.Speed of rotation of work piece (150 rpm, 420 rpm, 710
rpm)
Here the model is defined as frictional model. That is heat is generated due to contacting friction when machining. So we
define a contact element and target element. In this case, cutting tool is contact element (CONTA175) and work piece is
the target element (TARGE170) and a node to surface contact is obtained. The coefficient of friction is given as 0.5 and
contact behaviour is asymmetric.
CONTA175 may be used to represent contact and sliding between two surfaces (or between a node and a surface, or
between a line and a surface) in 2-D or 3-D. The element is applicable to 2-D or 3-D structural and coupled field contact
analyses. This element is located on the surfaces of solid, beam, and shell elements. 3D solid and shell elements with
midside nodes are supported for bonded and no separation contact. For other contact types, lower order solid and shell
elements are recommended.
Contact occurs when the element surface penetrates one of the target segment elements (TARGE169, TARGE170) on a
specified target surface. Coulomb friction, shear stress friction, user-defined friction with the USERFRIC subroutine, and
user- defined contact interaction with the USERINTER subroutine are allowed. This element also allows separation of
bonded contact to simulate interface delaminating.

Page | 10
Paper Publications
 ISSN 2393-8471

International Journal of Recent Research in Civil and Mechanical Engineering (IJRRCME)

Vol. 5, Issue 2, pp: (7-12), Month: October 2018 – March 2019, Available at: www.paperpublications.org

The below APDL commands are for changing the behaviours of contact elements.
KEYOPT, cid, 1, 1: This includes displacement and temperature degrees of freedom
KEYOPT, cid, 5, 3: This close gap or reduce penetration.
KEYOPT, cid, 9, 1: Exclude both initial penetration and gap.
KEYOPT, cid, 10, 2: Contact stiffness update on each iteration based.
The below APDL commands are for modifying the real constant sets. RMODIF, cid, 9, 500e6: This changes maximum
frictional stress in N/m2 RMODIF, cid, 14, 1e4: This changes thermal contact conductance between tool and work piece
in w/m2 °C
RMODIF, cid, 15, 1: This includes a real constant FHTG, the fraction of frictional dissipated energy converted into heat.
RMODIF, cid, 18, and 0.95: This gives fraction of frictional dissipated energy converted into heat.

Fig. 5

We use Modal Analysis to determine the vibration characteristics (Natural frequencies and mode shapes) of a structure of
a machine component while it is being designed. It also can be a starting point for another, more detailed, Dynamic
Analysis, such as a transient dynamic, a harmonic response analysis, or a spectrum analysis. Uses for Modal Analysis:
The Natural frequencies and mode shapes are important parameters in the design of a structure for Dynamic loading
conditions. They are also required if you want to do a spectrum analysis or a mode superposition harmonic or transient
analysis.
Open Ansys Workbench through Start All programs – Ansys – Workbench. Right Click on the mesh – Insert -Sizing,
Select Units from Units Menu as Metric (mm, kg, N, S etc.), Put the cursor on body sizing – select all objects by using
body and box selection method, select all by dragging a window –apply – Ok and keep the cursor on body sizing and
enter element sizing 10mm in bottom details window. Right Click on the mesh – Generate Mesh. The mesh will be
generated as shown below.
The temperatures obtained for high speed steel tool at various speed and depth of cut through FEA are summarized in
Table and graph below.
Table 3: Results and analysis

Speed (rpm) Depth of Cut (mm) Time (sec) Temperature (0C)

150 0.1 49 68.5
420 0.1 17.5 77
710 0.1 10 84
150 0.7 21.3 126.8
420 0.7 17.5 160
710 0.7 10 170
Page | 11
Paper Publications
 ISSN 2393-8471

International Journal of Recent Research in Civil and Mechanical Engineering (IJRRCME)

Vol. 5, Issue 2, pp: (7-12), Month: October 2018 – March 2019, Available at: www.paperpublications.org

Fig. 6

V. CONCLUSION
It can be observed that an increase of the cutting speed produces an increase of the cutting temperature. This result is due
to the fact that an increase of the cutting speed produces an increase of the cutting forces. More energy is needed to
remove the material away increasing the cutting temperature. It can be observed that an increase of the depth of cut
produces an increase of the cutting temperature. When a material is plastically deformed, most of the energy is turned into
heat since the material is subject to extremely severe deformations; being the elastic deformation the ones that represents a
small part of the total deformation. Hence, the increase of depth of cut represents a bigger compression in the tool-work
piece interface this will increase the energy supplied to the system during the cut of the material.
REFERENCES
[1] Shijun Zhang, Zhanqiang Liu, 2008. An analytical model for transient temperature distributions in coated carbide
cutting tools International Communications in Heat and Mass Transfer 35, 1311–1315.
[2] L.B.ABHANG and M. HAMEEDULLAH, 2010. Chip-Tool Interface Temperature Prediction Model for Turning
Process International Journal of Engineering Science and Technology Vol. 2(4), 382-393.
[3] J. E. JAM, V. N. FARD, 2011. A novel method to determine tool-chip thermal contact conductance in machining
International Journal of Engineering Science and Technology (IJEST) ISSN: 0975-5462 Vol. 3 No.12.
[4] Yash R. Bhoyar, Asst. Prof. P. D. Kamble, 2013. Finite element analysis on temperature distribution in turning
process using deform-3D International Journal of Research in Engineering and Technology ISSN: 2319-1163.
[5] Deepak Lathwal, Deepak Bhardwaj, 2013. Study and analysis of single point cutting tool under variable rake angle.
Vol. 1 Issue I, ISSN: 2321-9653. International journal for research in applied science and engineering technology
(IJRASET).
[6] Maheshwari N Patil, Shreepad Sarange, 2014.Numerical analysis to determine the distribution of tool forces and
temperatures of single point cutting tool. International Journal of Science and Research (IJSR) ISSN (Online): 2319-
7064.

Page | 12
Paper Publications