Finite element modeling of tool stresses on ceramic tools in hard turning

Hard turning process has been developed as a possible alternative instead of more expensive cylindrical grinding operations. This process involves many cutting conditions like traditional turning such as machining parameters, nose radius and tool geometry. This study aims that cutting force components (F-f, F-r, F-c) and cutting tool stresses depending on cutting conditions which are cutting speed, depth of cut and feed rate have been investigated in hard turning of DIN 1.2344 tool steel using uncoated ceramic tools. The experiments of hard turning were performed based on full factorial design. The distributions of cutting tools stresses were analyzed based on finite element method by using ANSYS software. ANOVA results showed that the most important factor on all cutting force components is the depth of cut while cutting speed has insignificant effect. In the results of study, it is shown that cutting tool image taken from ANSYS via finite element analysis and tool microscope are very similar. It is possible to say that the boundary conditions for loading of cutting force components are correct and the prediction of cutting tool stresses by finite element analysis can be determined in hard tuning processes.