Finite Element Method-Based Machining Simulation for Analyzing Surface Roughness During Turning Operation with HSS and Carbide Insert Tool

In this paper, FEM is used to investigate turning process on AISI 1020 steel by considering the effect of cutting speed, depth of cut, and feed on the surface roughness. Two different tools are used for turning, i.e. single-point cutting tool (HSS) and insert tool (CNMA WC). The FEM software DEFORM-2D is used to simulate the turning process. The results obtained by the simulation have been compared and analyzed with the experimental values. Overall minimum and maximum deviation between FEM model and experiment for single-point tool (HSS) are 3.74 and 22.8 %, respectively, and similarly for insert tool (CNMA WC) are 1.15 and 11.8 %, respectively.