Finite Element Modelling of Orthogonal Cryogenic Machining Process

The present work aims in creating the Finite Element Models for the conventional and the Cryogenic Orthogonal machining process. Finite Element Modelling (FEM) of the orthogonal machining operation was performed using DEFORM – 2D which is based on a modified Lagrangian formulation. Finite Element models were developed for various experimental conditions for both conventional and cryogenic orthogonal machining process. The response variables obtained from the models are cutting force, thrust force, temperature, shear stress, strain and strain rate. AISI 1045 steel is used as work material and for tool, tungsten carbide is used under various experimental conditions with the cutting speeds at 100 m/min, 150 m/min, 200 m/min and feeds at 0.07 mm/rev, 0.1 mm/rev, 0.14 mm/rev. A maximum temperature difference of 20.12% is obtained when conventional and cryogenic models were compared at a feed rate of 0.07 mm/rev and cutting speed of 150 m/min. cutting force and thrust force were higher for cryogenic model compared with that of the conventional model. Stress and Strain were distributed as expected to occur in the experiment.