A finite element based investigation of tool wear rate via machining of Al6061 alloys using deform-3D

The application of finite elements using Deform 3D in the turning of metals is very significant because it helps in the forecasting analysis before the production of products is made. This will help to eliminate material adhesion issues during the turning process, especially when working with aluminium materials. The aluminium 6061 alloys are extensively used in the engineering industry due to their lightweight and long-lasting properties, and it is one of these alloys that is regularly used due to its desirable qualities. Al6061 alloy, which is widely used in aerospace and building, needs precise machining to guarantee the best surface superiority. Tool wear sustained during machining has a direct impact on the surface quality of a machined component. This research utilized a finite element-based method using Deform 3D to investigate tool wear rate via machining of AL6061 alloys and also investigate the interactions between process parameters and tool wear with turning time analysis. The factors considered were depth of cut, cutting speed, and feed rate, and the response study was also analysed with regard to turning time. The L9 Taguchi orthogonal array was engaged in the methodology to design the experiments for the simulation study. The results obtained show that the time of machining and the internal machining factors are very important in resolving the problem of tool wear during the manufacturing of the mechanical device. At the highest variation time of cut, the optimal process parameters of 1800 rpm cutting speed, 3 mm depth of cut, and 2 mm/rev feed rate resulted in the lowest tool wear rate.