Investigating the Effect of Metal Working Fluid in Orthogonal Cutting of AISI 420 Stainless Steel Using 3-Dimensional Finite Element Model

To enhance the efficiency of a machining process, many experiments with several combinations of factors need to be conducted and it is a time consuming and expensive process. Finite element (FE) simulation is the best alternative to reduce the number of experiments. A coupled Eulerian-Lagrangian (CEL) model, which combines fluid and structure is in demand, and it is the nearest representation of the experiment. The present work uses CEL approach to analyse the variation of temperature at shear deformation zones, rake and flank surfaces with and without metal working fluid (MWF) in machining of 420 stainless steel workpiece. The cutting forces were also predicted using these simulations. Some of the simulations were validated with literature and the rest were validated with the experiments. The developed cutting fluid combination was showing a larger reduction in temperature as compared to dry cutting. This methodology will give a scientific base for realistic simulation of the machining process.