Surface Roughness Investigation and Stress Modeling by Finite Element on Orthogonal Cutting of Copper

In this work, a modern non-contacting optical technique was used to study the surface roughness of
commercially pure copper. Finite element (FE) method was applied to predict the stress during
orthogonal cutting by simulating the machining process. The experimental work empathized mainly on
the effect of cutting speed (N) and feed rate (f) on surface roughness of copper. Scanning electron
microscope (SEM) was utilized to evaluate the surface variations at different machining conditions.
Johnson-Cook mathematical model was adopted and employed to determine the parameters of the
material. Furthermore, the maximum Von-Mises stress was predicted as a function of machining
conditions. A software package of code (ABAQUS/CAE) was used for the analysis and response
surface methodology (RSM) was applied to visualize the results. The results showed a significant
effect of the feed rate/cutting speed interaction on surface roughness and Von-Mises stress of copper.
An enhancement of 14% in surface roughness was perceived with increasing the cutting speed. A
good agreement was observed between experimental and analytical results.