Results and Discussion

Results And Discussion

STRESS ANALYSIS

FEA simulations were performed to evaluate the equivalent von Mises stress distribution in the cutting tool under simulated cutting conditions. Appropriate boundary conditions were applied to replicate fixed tool-holder constraints, and cutting forces were simulated as loads at the tool tip. Mesh sensitivity was considered to ensure result accuracy.

The distribution of equivalent von Mises stress under various cutting conditions is illustrated in Figure 3, highlighting the influence of speed, tool radius, and depth of cut on stress concentration zones.

Modal Analysis

Modal analysis was conducted on tool profiles. Natural frequencies and mode shapes were extracted to observe the effects of wear and varying input parameters on vibrational characteristics.

The variation in Mode 10 natural frequencies corresponding to different combinations of cutting speed, tool-tip radius, and depth of cut is summarized in Table 3, revealing the sensitivity of vibrational characteristics to process parameters.

In Figure 4, the bar chart shows the relationship between tool tip radius (mm) and the resulting vibration frequency (Hz) for the run oders 1, 2 and 3. As the tool tip radius increases, a noticeable rise in vibration frequency is observed, indicating a direct correlation between these two parameters during the cutting process. 

This Figure 5 illustrates the variation in vibration frequency (Hz) with respect to different depths of cut (mm). A clear increasing trend in vibration frequency is observed as the depth of cut increases, suggesting that deeper cuts lead to higher dynamic responses during machining.