Finite Element Analysis of Orthogonal Cutting of AISI 1045 Steel under Dry and Cryogenic Condition

The major needs in machining are high material removal rate, good surface finish and low tool wear. These objectives can be achieved by reducing the cutting temperature. Cryogenic cooling is an environmental friendly clean technology for desirable control of cutting temperature. In this study, an attempt is made to develop a finite element model for orthogonal cutting operation of AISI 1045 steel at different speed-feed combinations under dry and cryogenic cutting conditions. The FEA simulated cutting temperature, cutting force, chip thickness and shear angle of dry and cryogenic cutting were compared. The present work shows the substantial benefit of cryogenic cooling on cutting temperature up to 30% over dry machining. Application of this cryogenic cooling was found to be more effective in cutting speed rather than a feed rate.