A Study on Surface Quality and Stress-State in Rotational Turning of Steel 45 Using Experimental and FEM Approaches

Karibek T. Sherov; Zhanara K. Mussina; Almat A. Sagitov; Galiya T. Itybayeva; Assylkhan V. Mazdubay; Aibek K. Sherov; Dinara Sh. Kossatbekova; Sayagul O. Tussupova; Assylbek Zh. Kassenov

doi:10.48084/etasr.12397

Authors

Karibek T. Sherov S. Seifullin Kazakh Agrotechnical Research University, Astana, Kazakhstan
Zhanara K. Mussina Toraighyrov University, Pavlodar, Kazakhstan
Almat A. Sagitov S. Seifullin Kazakh Agrotechnical Research University, Astana, Kazakhstan
Galiya T. Itybayeva Toraighyrov University, Pavlodar, Kazakhstan
Assylkhan V. Mazdubay Toraighyrov University, Pavlodar, Kazakhstan
Aibek K. Sherov S. Seifullin Kazakh Agrotechnical Research University, Astana, Kazakhstan
Dinara Sh. Kossatbekova S. Seifullin Kazakh Agrotechnical Research University, Astana, Kazakhstan
Sayagul O. Tussupova Toraighyrov University, Pavlodar, Kazakhstan
Assylbek Zh. Kassenov Toraighyrov University, Pavlodar, Kazakhstan

Volume: 15 | Issue: 6 | Pages: 28502-28510 | December 2025 | https://doi.org/10.48084/etasr.12397

Received: 3 June 2025 | Revised: 11 August 2025 | Accepted: 25 August 2025 | Online: 29 September 2025

Corresponding author: Zhanara K. Mussina

Abstract

This study investigates a method for the rotational turning of external cylindrical surfaces with a particular focus on evaluating the quality of the machined surface and its stress state during the turning of 45 steel, using experimental methods and the Finite Element Method (FEM). The influence of the cutting modes on the quality indicators during rotary turning was analyzed, and their optimal values for the processing of steel 45 were determined. The results indicate that an increase in the spindle speed has a positive impact on the roughness of the machined surface, but a negative effect on hardness. Increasing the feed rate has an ambiguous impact on the quality indicators of the machined surface: it improves the roughness but reduces the hardness. With an increase in the cutting depth, both quality indicators deteriorate. In addition, using the ANSYS/LS-DYNA (Ls Pre-Post) software package, the stress-strain state of the steel 45 workpiece was calculated, and the temperature change in the cutting zone, in the chips, and on the machined surface during rotational turning was determined. This revealed that the maximum equivalent Mises stress is 1.1 MPa and the maximum temperature in the cutting zone is 287 °C. It was observed that when the cutting force fluctuates within the range of 4.8 kN-5.1 kN, the vibration occurring in the cutting zone is reduced. The results of this study indicated that rotary machining allows for increased feed, depth, and cutting speed without critical tool wear, which directly increases the productivity. It also reduces the tooling, energy, machining time, and rework costs, resulting in significant economic benefits.

Keywords:

rotational turning, roughness, hardness, cutting conditions, temperature, stress-strain state, cutting force

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