Numerical investigation of dimple-texturing on the turning performance of hardened AISI H-13 steel

Abstract

Forming micro-dimples nearer to the cutting edge on the rack face of the tungsten carbide cutting inserts will positively influence the machinability. However, it is challenging to machine the perfect micro-dimple dimensions by utilizing the available machining techniques. Finite element analysis can be an efficient way to observe the influence of dimple-texture area density, micro-dimple size, and various micro-dimple shapes on cutting inserts' machinability. This paper numerically analyses the impact of micro-dimple-textured cutting inserts in dry machining of AISI H-13 steel using AdvantEdge (virtual machining and finite element analysis software). Micro-dimples are formed on the rack face of tungsten carbide cutting inserts to observe the effect of dimple-textured cutting inserts on machinability compared to non-textured cutting inserts in terms of micro-dimple shape, micro-dimple size, and micro-dimple area density ratio. Their outcomes are analysed in terms of chip-insert contact length, main cutting force, and thrust force. It is observed that micro-dimple textured cutting inserts exhibit minimal main cutting force and thrust force in line with increasing the cutting insert life span. The abrasive wear was reduced in dimple-textured cutting inserts due to minimal contact between the cutting insert and chip developed compared to non-textured cutting inserts.