A Finite Element Analysis of Orthogonal Machining Using Different Tool Edge Geometries

By M. Tawfiq, S. Shahab. Engineering and Technology Journal, 2007

148 citations recorded by the source corpus.

This paper summarizes the effects of edge preparation of the cutting tool in orthogonal cutting on the following variables: stress distributions at the tool rake face, cutting forces and tool-chip contact length. The Finite Element Method (FEM) is selected using the ANSYS /V4.5 code. Six models of cutting tools have been suggested having edge radii of (0.01, 0.05, 0.1, 0.15, 0.2, and 0.25) mm. The results obtained provide a fundamental understanding of the process mechanics for cutting with realistic cutting tool edge radius in order to assist in the optimization of tool edge design. The results show that the optimum edge radius from the six simulated models is (0.05) mm; this edge radius gives minimum value of effective stress. The results show also that the optimum edge radius that shows minimum tangential cutting and feed forces is (0.01) mm. The results investigated that the tool-chip contact length is increased, until reaching maximum value of (2.4) mm at (r=0.15mm), and minimum value of (0.75) mm at (r=0.01mm). The maximum relative difference between simulated results of this work and other previous paper results is (2% - 17%) for the tool effective stresses, (5%) for the tangential force, and (11%) for the feed force.

Subfields: Biomedical Engineering, Mechanical Engineering

View Paper: https://www.semanticscholar.org/paper/d48ed319bab02cd9dc2a17e572d4e2f88a1339d3

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Citations in the corpus

Size effects in manufacturing of metallic components (2009, methodology): “[184] in a follow-up work, used a range of tool edge configurations including chamfer and hone radius conditions and simulated the material flow by calculating the stresses, strains and temperatures.”
SURFACE INTEGRITY CHARACTERIZATION AND PREDICTION IN MACHINING OF HARDENED AND DIFFICULT-TO-MACHINE ALLOYS: A STATE-OF-ART RESEARCH REVIEW AND ANALYSIS (2009, background): “The importance of size effect such as cutting edge radius on the prediction of residual stress has been well recognized (Ee et al., 2005; Guo and Wen, 2005; Nasr et al., 2007; Outeiro et al., 2006; Yen et al., 2004).”
A new material model for 2D numerical simulation of serrated chip formation when machining titanium alloy Ti–6Al–4V (2008, unknown): “Therefore, apart from pure deformation model [9,10], a fracture criterion is implemented in most numerical simulations to obtain the saw-tooth chip geometry [12,14–19].”
Comparison of tool life between ceramic and cubic boron nitride (CBN) cutting tools when machining hardened steels (2009, methodology): “(2000), Yen et al.(2004), pointed out that, the most likely dominant parameters were workpiece hardness, steel microstructure, CBN content, and edge geometry.”