Finite Element Numerical Simulation Analysis of Tool Strength

**1. Introduction** The metal cutting process involves the interaction between the cutting tool and the workpiece. Within the machining system, which includes machine tools, fixtures, tools, and workpieces, the proper use of tools is crucial. The overall structure, cutting edge material, and geometry of the tool directly influence tool life, machining quality, and production efficiency. Therefore, in the cutting process, the tool must possess high strength, good toughness, long service life, and favorable machinability. Conducting a theoretical analysis of tool strength helps understand the internal stress and strain distribution, which not only aids in selecting the appropriate tool for machining but also provides a foundation for further improving the internal force state and extending the tool's lifespan. **2. Introduction to Finite Element Numerical Analysis Software ANSYS** ANSYS is a finite element numerical analysis software that integrates modern mathematical and mechanical theories with finite element techniques, computer graphics, and optimization methods. It offers a comprehensive library of elements, material models, and solvers, making it suitable for various numerical simulations. This software efficiently solves structural dynamics, static forces, linear, and nonlinear problems. As a leading CAE tool, ANSYS has become an essential part of CAD/CAM/CAE software systems today. When used for mechanical analysis, ANSYS analyzes stress and strain concentration areas through numerical simulation of applied loads, enabling strength analysis and optimization design. The three main steps in the ANSYS solution process are: creating a finite element model (preprocessing), applying loads and solving (solving), and viewing the results (postprocessing). **3. Establishment of Tool Mechanics Model** During the metal cutting process, the force required to deform the material and form the chip is known as the cutting force. The magnitude of this force directly affects the design and usage of tools, machine tools, and fixtures. The cutting force consists of resistance from elastic and plastic deformation, friction on the tool’s rake face against the chip, and friction between the tool’s flank and the machined surface. To facilitate analysis and measurement, a space rectangular coordinate system can be established based on the direction of the main cutting speed, depth of cut, and feed direction. The total cutting force Fr is decomposed into three components: the main cutting force Fz (tangential force in the cutting speed direction), the depth-of-cut resistance Fy (radial force in the depth direction), and the feed resistance Fx (axial force in the feed direction). Fz is the largest component and serves as the basis for tool design and usage. It is also used to check the strength and stiffness of machine tool components and motor power. Fy does not consume power but affects process system deformation and machining quality. If the system rigidity is insufficient, Fy may cause deformation and vibration. Fx acts on the feed system and is critical for checking the strength and rigidity of the machine tool. **4. Example of Tool Strength Finite Element Analysis** Turning tools are among the most commonly used metal cutting tools, primarily for turning rotary surfaces and end faces. This example uses ANSYS to perform finite element analysis on a typical external turning tool. (1) **Test Parameters**: A carbide turning tool was used on a C630 lathe to turn carbon steel. The tool bar material is 45 steel, with dimensions B×H=20mm×25mm, L=150mm. The blade material is YT15, with a front angle of 15°, back angle of 6°, and nose radius of 0.8mm. The tool material properties include a tensile strength of 600 MPa, yield strength of 355 MPa, modulus of elasticity E=206 GPa, and Poisson’s ratio of 0.27. Cutting parameters were: cutting speed vc=100 m/min, feed f=0.5 mm/r, and depth of cut ap=2 mm. (2) **Mesh Generation**: A solid model of the turning tool was created in ANSYS interactive mode. Using the self-adaptive mesh division method, the tool was divided into 1569 nodes and 6,934 units with an eight-node hexahedral Solid45 unit type. The mesh was denser near stress concentration areas. Assumptions made during the simulation included: linear elasticity, no yield, static stress distribution, and neglect of temperature effects. (3) **Loading and Simulation**: Based on empirical formulas from literature, the cutting force components were calculated. The worst-case scenario was simulated, with the force acting at the tool tip. All constraints were applied at the tool shank. (4) **Result Analysis**: The stress distribution diagram (Fig. 3), strain distribution (Fig. 4), and displacement contour (Fig. 5) were obtained. The maximum stress was found at the tool nose (node 21), with a value of 676 MPa. The maximum strain was 0.00426 m, and the maximum displacement was 0.609 mm. Under extreme conditions, the maximum stress slightly exceeded the strength limit but remained within acceptable limits. Nonlinear analysis would provide more accurate results. The tool tip, being the stress concentration point, is prone to failure, highlighting the need for high-strength blade materials and careful parameter adjustment to avoid excessive stress and ensure stable cutting. **5. Conclusion** Using ANSYS for finite element analysis allows precise understanding of the force distribution across the tool, identifying stress and strain patterns and locating critical points. This approach supports improved tool design, failure analysis, and enhanced tool performance. The analysis of the turning tool demonstrated the effectiveness of ANSYS in simulating complex stress conditions that traditional methods struggle to handle. This technique has significant practical value and can be extended to other tools and components, especially when nonlinear dynamic analysis is employed for more accurate results.

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