The machining process is employed to transform a workpiece into a predefined
geometry with the assistance of a cutting tool. Throughout this process, the
cutting tool undergoes various adverse effects, including deformation, stress,
thermal gradient, and more, all of which impact tool sharpness, surface finish,
and tool life. These outcomes are also influenced by cutting parameters,
specifically cutting speed, feed rate, and depth of cut. The present
investigation aims to demonstrate the application of ANSYS analysis software in
predicting stress, deformation, thermal gradient, and other factors on the tool
insert tip for various machining parameters. To achieve this, an experimental
setup was arranged to collect cutting force and temperature data using a
dynamometer and thermocouples during the machining process of maraging steel
with a tungsten carbide tool insert. Experiments were conducted with different
combinations of machining parameters using design of experiments (DoE). The
measured cutting forces and temperatures for various machining parameters served
as input for the analysis of stress, deformation, temperature gradient, and heat
flux. The effects of these parameters are tabulated, and inferences are made for
optimization.