Surface Roughness Investigation and Stress Modeling by Finite Element on Orthogonal Cutting of Copper

Abstract

In this paper, a modern non-contacting optical technique was used to study the surface roughness of commercially pure copper. Finite element (FE) method was applied to predict the stress during orthogonal cutting by simulating the machining process. The experimental work empathized mainly on the effect of cutting speed (N) and feed rate (f) on the surface roughness of copper. Scanning electron microscope (SEM) was utilized to evaluate the surface variations at different machining conditions. Johnson-Cook mathematical model was adopted and employed to determine the parameters of the material. Furthermore, the maximum Von-Mises stress was predicted as a function of machining conditions. A software package of code (ABAQUS/CAE) was used for the analysis and response surface methodology (RSM) was applied to visualize the results. The results showed a significant effect of the feed rate/cutting speed interaction on surface roughness and Von-Mises stress of copper. An enhancement of 14% in surface roughness was perceived with increasing the cutting speed. A good agreement was observed between experimental and analytical results.