Influence of Machining Parameters on Tungsten Carbide Inserts in ANSYS Analysis of Maraging Steel Machining 2024-01-5057

The machining process is employed to transform a workpiece into a predefined geometry with the assistance of a cutting tool. Throughout this process, the cutting tool undergoes various adverse effects, including deformation, stress, thermal gradient, and more, all of which impact tool sharpness, surface finish, and tool life. These outcomes are also influenced by cutting parameters, specifically cutting speed, feed rate, and depth of cut. The present investigation aims to demonstrate the application of ANSYS analysis software in predicting stress, deformation, thermal gradient, and other factors on the tool insert tip for various machining parameters. To achieve this, an experimental setup was arranged to collect cutting force and temperature data using a dynamometer and thermocouples during the machining process of maraging steel with a tungsten carbide tool insert. Experiments were conducted with different combinations of machining parameters using design of experiments (DoE). The measured cutting forces and temperatures for various machining parameters served as input for the analysis of stress, deformation, temperature gradient, and heat flux. The effects of these parameters are tabulated, and inferences are made for optimization.