Finite Element Analysis on Machining of Magnesium Alloys

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Force measurement in metal cutting is an essential requirement as it is related to machine part design, tool design, power consumptions, vibrations, part accuracy, etc. It is the purpose of the measurement of cutting force to be able to understand the cutting mechanism such as the effects of cutting variables on the cutting force, the mach inability of the work piece, the process of chip formation, chatter and tool wear. This project presents a simulation model for estimation of cutting forces in turning process. A 3D simulation model was used for predicting the cutting forces as it is more nearer to practical process than the two dimensional model, although computing time is very large for a 3D model. A 3D model for oblique cutting is used and model to analyze turning of MAGNESIUM ZE41A using a HSS inserts was developed using ANSYS software. The finite element analysis incorporated the elastic and plastic properties of the work material in machining and Johnson-cook model is used for cutting simulation. The results from simulation model were compared with experimental data. It is found that simulation results were in good agreement with experimental results.