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IJMERR 2025 Vol.14(2):163-175
doi: 10.18178/ijmerr.14.2.163-175

Simulation and Optimization of Von-Mises Stress and Tip Deformation for Single Point Cutting Tool Geometry during Turning

Ashish Soni 1,*, Pankaj Kumar Das 1, Mohammad Yusuf 2,3,*, Hesam Kamyab 4,5, Mohammad Azad Alam 6, Moinul Haq 7, Yassine Ezaier 8, and Hussameldin Ibrahim 2
1. Centre for Additive Manufacturing, Chennai Institute of Technology, Chennai, Tamil Nadu, 600069, India
2. Clean Energy Technologies Research Institute (CETRI), Process Systems Engineering, Faculty of Engineering & Applied Science, University of Regina, 3737 Wascana Parkway, SK, S4S 0A2, Canada
3. Centre of Research Impact and Outcome, Chitkara University Institute of Engineering and Technology, Chitkara University, Punjab, India
4. Department of Biomaterials, Saveetha Dental College and Hospital, Saveetha Institute of Medical and Technical Sciences, Chennai 600077, India
5. The KU-KIST Graduate School of Energy and Environment, Korea University, 145 Anam-Ro, Seongbuk-Gu, Seoul, 02841, Republic of Korea
6. Interdisciplinary Research Centre for Sustainable Energy Systems (IRC-SES), King Fahd University of Petroleum and Minerals (KFUPM), 31261, Dhahran, Saudi Arabia
7. Interdisciplinary Research Center for Construction and Building Materials (IRC-CBM), Research Institute, King Fahd University of Petroleum & Minerals, Dhahran, 31261, Saudi Arabia
8. Bio-Geosciences and Materials Engineering Laboratory, Ecole Normale Supérieure, University Hassan II, Casablanca, Morocco
Email: ashishsoni@citchennai.net (A.S.); researchnita2019@gmail.com (P.K.D.);
mohd.yusuf@uregina.ca (M.Y.); hesam_kamyab@yahoo.com (H.K.), mohammad.alam@kfupm.edu.sa (M.A.A.), mohdmoinul.haq@kfupm.edu.sa (M.H.), yassine.ezaier14@gmail.com (Y.E.),
hussameldin.ibrahim@uregina.ca (H.I.)
*Corresponding author

Abstract—The study aimed to quantify the values of von-mises stress and tip deformation of single point cutting tools of different tool geometries. Pro e Creo 5.0 was used for modeling the cutting tools and simulations were carried out through ANSYS 14.5. Three different materials for cutting tools namely, Cubic Boron Nitride (CBN), High-Speed Steel (HSS), and Gray cast iron having rake angles in the range of 1º–6º, 10º–15º and 20º–25º, respectively were taken for analyses. The rake angles were varied with a unit increment under the considered ranges with corresponding edge radii of 0.25, 0.20, 0.15, 0.10, 0.05, and 0.01 mm for each tool material. The cutting force was constant at 100 N considering engineering stress. The cutting speed of 2.54 m/s and a feed rate of 0.25 mm/revolutions were taken for the simulations of the cutting tool models. The minimum von-mises stress and tip deformation for CBN, HSS, and gray cast iron cutting tools were obtained at an edge radius of 0.15 mm having rake angles of 3º, 12º, and 22º, respectively. The resulted values have provided an estimation for von-mises stress and tip deformation thereby, assisting in improving the machinability, saving energy requirements, and preventing tool failures.

Keywords—von-mises stress, simulation, finite element, tool geometry, single point cutting tool, machinability

Cite: Ashish Soni, Pankaj Kumar Das, Mohammad Yusuf, Hesam Kamyab, Mohammad Azad Alam, Moinul Haq, Yassine Ezaier, and Hussameldin Ibrahim, "Simulation and Optimization of Von-Mises Stress and Tip Deformation for Single Point Cutting Tool Geometry during Turning," International Journal of Mechanical Engineering and Robotics Research, Vol. 14, No. 2, pp. 163-175, 2025. doi: 10.18178/ijmerr.14.2.163-175

Copyright © 2025 by the authors. This is an open access article distributed under the Creative Commons Attribution License which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited (CC BY 4.0).