Surface Roughness Investigation and Stress Modeling by Finite Element on Orthogonal Cutting of Copper

To study the surface roughness of commercially pure copper, a modern non-contacting optical technique was used in this work. The finite element (FE) technique was applied by simulating the machining process to predict the stress during orthogonal cutting. The experimental work focused primarily on the impact of the cutting speed (N) and the feed rate (f) on copper surface roughness. To evaluate surface variations under different machining conditions, the scanning electron microscope (SEM) was used. The mathematical model of Johnson-Cook was adopted and employed to determine the material parameters. In addition, as a function of machining, the maximum Von-Mises stress was projected The circumstances. For the analysis and response surface methodology (RSM) to visualise the outcomes, a software package of code (ABAQUS/CAE) was used. The findings showed an important impact of the interaction of feed rate/cutting speed on surface roughness and copper stress from Von-Mises. By increasing the cutting speed, a 14 percent improvement in surface roughness was observed. A good agreement between the experimental and analytical results was observed. Circumstances. For the study and response surface methodology (RSM) to visualise the findings, a software package of code (ABAQUS/CAE) was used. The results showed a substantial impact on surface roughness and Von-Mises copper stress from the feed rate/cutting speed interaction. By increasing the cutting speed, a 14% increase in surface roughness was perceived. A strong agreement between experimental and analytical findings has been observed. The terms. For the analysis and response surface methodology (RSM) to visualise the effects, a software package of code (ABAQUS/CAE) was used. The results showed a major effect of the interaction between feed rate/cutting speed on surface roughness and copper stress from Von-Mises. By increasing the cutting speed, an increase of 14 percent in surface roughness was perceived. A strong agreement between experimental and analytical findings has been noted.

Author (s) Details

Hussein Zein
Mechanical Engineering Department, College of Engineering, Qassim University, Saudi Arabia and Mechanical Design and Production Department, Faculty of Engineering, Cairo University, Giza 12613, Egypt.

Osama M. Irfan
Mechanical Engineering Department, College of Engineering, Qassim University, Saudi Arabia and Mechanical Engineering Department, Beni Suef University, Beni Suef 62764, Egypt.


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