Analysis of Geometrical and Machining Parameters in Turning AISI 1045 Steel Using Deform-2D

Modern manufacturing industries are concerned about producing quality components, with reduced production cost. To achieve this, the machining parameters and tools selected for machining a particular material should yield better results. During machining, flank wear occurring at the cutting insert is the predominant factor that causes poor surface finish, is responsible for the dimensional inaccuracy of the machined surface. In this work an attempt has been made to minimize flank wear of an uncoated carbide insert while machining AISI 1045 steel by finite element analysis. Three levels of machining and geometrical parameters, varied through 3 levels are chosen. An L₁₈ orthogonal array is selected based on Taguchi's design of experiment. Finite element analysis is carried out using DEFORM-2D, a simulation and analysis software and the output quality characteristics are analyzed using signal-to-noise ratio and analysis of variance (ANOVA). A validation simulation analysis is performed based on the optimum condition obtained.