FEA modeling and prediction of surface roughness of aluminum alloy (LM4) during turning process

Abstract

Different cutting parameters have different influences on the surface finish. A study of effect of some of these parameters on the surface roughness of Aluminum alloy grade LM4 (AlSi5Cu3) is carried out in this work. In the experiment conducted, six values of cutting speed, three values of depth of cut, six values of feed and two values of tool nose radius are used. The experimentation was carried out using a three factor experiment principle from design of experiment. The chemical composition of the work material was tested using arc spectrometer and verified to be of grade LM 4. The values of parameters like cutting speed, feed rate and depth of cut were selected from the recommended ranges from the tool manufacturer catalogue. The test pieces were turned on a center lathe machine under different levels of these parameters. The surface roughness of the machined surface was measured using surface measurement tester. From the analysis of results the relationship between surface roughness and equivalent stress is established.