Previsão das tensões térmicas em ferramenta de corte durante processo de torneamento

Abstract

The turning process, as one of the initial phases of machining a part, requires high quality execution guaranteed through the correct dimensions measurement. Any failure in this stage of part production generates failures in the process chain that will lead to future product non-conformity and, consequently, financial loss to the industry. To ensure its efficiency, one of the parameters to be monitored and controlled is the quality of the cutting tools (inserts). Calculations of tool life, analysis of its cutting capacity, as well as forms and intensities of wear must be performed to have better control of the production process. In view of this, the objective of the research was to elucidate the machining process in its types of machining, parameters and theoretical formulations; to analyze cutting and chip formation specifically in turning; as well as the types of insert, their functions in the process and the wear they may suffer. The study was also carried out on the causes generating each wear and its consequences. To validate the theoretical results obtained, thermal and structural simulations were performed using the Finite Element Method (FEM) of the inserts for comparison with the literature, using machining conditions used on a lathe to manufacture an input shaft for truck and bus transmissions. With this, the maximum temperatures in the tool and the regions of stress concentration on the upper surface where crater wear can occur, and on the clearance surfaces and cutting edge, where flank and notch wear can occur, respectively, were obtained.