Finite element modeling of power consumption in turning of AISI 1040 steel
Abstract
AISI 1040 stainless steel is well known for its immense strength and favorable resistance to corrosion. On the other hand, a difficult workability process during machining operations causes a high-power consumption. Energy consumption is an important expense in the machining process. Therefore, this study is aimed to model the power consumption of AISI 1040 stainless steel by using the finite element method. The Third Wave Systems AdvantEdge program was applied for finite element analysis. This program which provides numerous design and analysis tools is specially designed to simulate cutting processes. Optimum cutting parameters to minimize the power usage were developed in three levels based on the Taguchi L9 experimental design. The Taguchi L9 orthogonal array was used as an experimental design. Finite element simulations were performed with three different cutting parameters feed rate (f), cutting speed (V), and cutting depth (a). As a result of Taguchi analysis based on S / N ratios, S / N graphs, S / N response table, ANOVA results, it was determined that progression speed is the most critical parameter in energy consumption.
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