By Ahmad Shahir Jamaludin, Abdullah Yassin
Keywords: Finite element method (FEM), 2D orthogonal end milling, cutting force prediction, cutting temperature prediction, friction model
The term machinability of workpiece materials relates to the easiness of a metal to be machined to an adequate surface finish. This paper clarified the analysis of laser sintered material machinability with mean of predicted cutting force and temperature distribution. 2D orthogonal cutting was employed on edge design tools with updated Lagrangian coupled thermo mechanical plane strain model. Adaptive meshing, tool edge radius and various types of friction models were assigned to obtain precise cutting results. Cutting force and cutting-edge temperature estimated by FE analysis are validated against corresponding experimental values by previous researchers. From the study, cutting force increases when radial depth increases and lowest error acquired when the shear friction factor of 0.8 was applied. Machining simulation for laser sintered materials estimated lower cutting force compared to mild steel AISI1055 due to lower Young modulus. Higher cutting temperature estimated for machining simulation laser sintered material compared to machining simulation mild steel AISI1055 due to its low thermal conductivity.