Análise por elementos finitos das tensões atuantes no inserto de corte aplicado em diferentes posições

Abstract

Machining processes, especially turning, are widely applied in the metalworking industry due to their efficiency in shaping components with high dimensional accuracy and surface quality. In this context, the performance of the cutting tool plays a crucial role in the quality of the operation, being influenced by factors such as the tool's positioning relative to the workpiece. Structural analyses through computational simulations, such as Finite Element Analysis (FEA), have proven to be valuable tools for understanding and predicting the mechanical behavior of components under different operating conditions. This study aimed to analyze, through FEA-based simulations, the stress distribution acting on a cemented carbide cutting insert subjected to different vertical positions in relation to the geometric center of the workpiece during the longitudinal turning process. Five distinct tool height configurations were investigated: two positions below center, two above, and one neutral position aligned with the center of the part, in order to assess the thermomechanical impacts on stress distribution within the insert. The results showed that deviations from the neutral position—both above and below—lead to increased stress concentrations, particularly near the cutting edge, favoring wear and potential localized failures. The neutral position exhibited more homogeneous stress distribution and better thermal dissipation, indicating superior structural performance. The analyses confirmed that even small variations in tool height significantly affect the mechanical and thermal behavior of the system, and that FEA is a valuable resource for predictive diagnostics in machining. Limitations of the study include simplifications in the model, such as the absence of chip breaker and coating. Nonetheless, the findings offer technical support for practical decisions in the manufacturing environment, such as the strategic reuse of inserts and precise tool holder calibration.