Title: FEM simulation for determining suitable parameters for dimple structure fabrication in turning process

Authors: Mohd Nor Azam Bin Mohd Dali; Jaharah A. Ghani; Che Hassan Che Haron; Sharudin Bin Hassan

Addresses: Politeknik Ungku Omar, Jalan Raja Musa Mahadi, 31400, Ipoh, Perak, Malaysia; Department of Mechanical and Material Engineering, Faculty of Engineering and Built Environment, Universiti Kebangsaan Malaysia, 43600 Bangi, Selangor, Malaysia ' Department of Mechanical and Material Engineering, Faculty of Engineering and Built Environment, Universiti Kebangsaan Malaysia, 43600 Bangi, Selangor, Malaysia ' Department of Mechanical and Material Engineering, Faculty of Engineering and Built Environment, Universiti Kebangsaan Malaysia, 43600 Bangi, Selangor, Malaysia ' Politeknik Ungku Omar, Jalan Raja Musa Mahadi, 31400, Ipoh, Perak, Malaysia; Department of Mechanical and Material Engineering, Faculty of Engineering and Built Environment, Universiti Kebangsaan Malaysia, 43600 Bangi, Selangor, Malaysia

Abstract: Surface texturing in the form of dimples for mechanical components is very important in enhancing those tribological properties which are closely associated to wear and friction. This paper presents the application of Third Wave AdvantEdge software in identifying the turning parameters for dimple structure fabrication. Approximately 20 ranges of cutting parameters of speed and feed rate were tested to obtain the cutting force vs. the length of cut to assist in the rough estimation of the size of the dimple structure before the actual machining was performed. In addition, a simulation using a low dynamic frequency of 15-25 Hertz was carried out in order to evaluate the ability and stability of the vibration-assisted tooling that had been developed in-house. The shape of the cutting force graph obtained from the simulation indicated that the machining parameters of cutting speed of 7-9 m/min, feed rate of 0.4-0.6 mm/rev and depth of cut of 0.01-0.05 mm were found to be suitable for the fabrication of dimples on A3xx casting aluminium alloy.

Keywords: Third Wave; dimple structure; surface texturing; FEM; finite element method; simulation; turning; tribology; cutting speed; feed rate; cutting force; length of cut; vibration-assisted tooling; casting alloys; aluminium alloys.

DOI: 10.1504/IJMPT.2016.079199

International Journal of Materials and Product Technology, 2016 Vol.53 No.3/4, pp.218 - 230

Received: 24 Feb 2016
Accepted: 15 Apr 2016
Published online: 22 Sep 2016 *

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