A three-dimensional finite element-approach to investigate the optimum cutting parameters in machining AA2024

Hassan Ijaz, Muhammad Asad, Saeed Rubaiee

Research output: Contribution to journalArticlepeer-review

4 Citations (Scopus)
14 Downloads (Pure)


This research work presents a numerical study of the orthogonal cutting process employing a finite element approach to optimize dry machining of aluminium alloy 2024. The main objective of the research work is to perform three-dimensional finite element simulations for a better understanding of temperature distribution and residual stresses development in the workpiece and tool regions along depth of cut direction. While, two-dimensional models don't predict true picture of aforesaid parameters along cutting depth due to material's out of plane flow and deformation. In the present study, effects of tool rake angles (7°, 14°, 21°) and cutting speeds (200, 400, 800 m/min) upon variations in chip geometry at various sections along workpiece width (depth of cut) have been discussed at large. Furthermore, cutting forces and tool-workpiece temperature profiles are also in depth analysed. The findings will lead the manufacturers to better decide post machining processes like heat treatment, deburring, surface treatments, etc. The results showed that a combination of a rake angle of 14° at cutting velocity of 800 m/min produces serrated chip segments with relatively moderate cutting forces in comparison to other parametric combinations. The efficacy of the presented finite element model is verified by comparing the numerically obtained results with experimental ones.
Original languageEnglish
Article number615
Number of pages14
JournalMechanics and Industry
Issue number6
Publication statusPublished - 4 Dec 2020
Externally publishedYes

Bibliographical note

Copyright on any article published from 2021 in Mechanics & Industry is retained by the author(s) under the Creative Commons license, which permits unrestricted use, distribution, and reproduction in any medium provided the original work is properly cited.


This research was funded by the Deanship of Scientific Research (DSR), University of Jeddah, Jeddah, with grant No. UJ-02-005-DR.


  • Finite element analysis
  • damage evolution
  • machining process
  • material modelling
  • AA2024

ASJC Scopus subject areas

  • Mechanical Engineering
  • Materials Science(all)
  • Industrial and Manufacturing Engineering


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