A parametric investigation of surface defect turning process: a simulation study

Recent developments in the field of manufacturing have led to a renewed interest in the new machining operations such as surface defect machining. Surface quality is a major problem in machining environment. Several attempts have been made to increase machining efficiency. Studies of surface defect machining show the importance of the method but these studies have not dealt with different defect parameters. There is little published data and very little is currently known about surface defect machining. In this study, surface defect turning process was investigated by designing different types of defects on the AISI-4340 workpiece. In this context, a two-dimensional simulation study was carried out. Different defect shapes and defect sizes were designed in the simulation study. The other machining parameters were kept constant. The results of cutting forces (F x , F y ), maximum cutting temperature and maximum effective stresses were compared. The present research explores, for the first time, the effects of different surface defect parameters. It was obtained that the cutting forces decreased in the surface defect turning. It was also observed that as the depth of the defect decreased, the cutting forces increased and the cutting temperature decreased. Also, the cutting forces decreased when the width of the defects increased. The thickness of the chips changed in the surface defect turning. A discontinuous chip formation was observed.