A finite element study of the effect of friction in orthogonal metal cutting

The process of orthogonal metal cutting is studied with the finite element method under plane strain conditions. A computational procedure has been developed for simulating orthogonal metal cutting using a general-purpose finite element code. The focus of the results presented in this paper is on the effect of friction on thermomechanical quantities in a metal cutting process. A series of finite element simulations have been performed, in which a modified Coulomb friction law is used to model the friction along the tool-chip interface, and a finite element nodal release procedure is adopted to simulate chip separation from the workpiece. A tool rake angle ranging from 15deg; to 30deg; and a friction coefficient ranging from 0.0 to 0.6 have been considered in the simulations. The results of these simulations are consistent with experimental observations in the literature. In particular, it is found that shear straining is localized in the primary shear zone while the material near the tool tip undergoes the largest plastic strain rate. However, the maximum temperature rise, which is induced by energy dissipation due to plasticity and friction, occurs along the tool-chip interface, not in the primary shear zone. Furthermore, the maximum temperature, the contact length, the shear angle, and the cutting force are found to depend strongly on the coefficient of friction.

[1]  K. Osakada,et al.  Process Modeling of Orthogonal Cutting by the Rigid-Plastic Finite Element Method , 1984 .

[2]  P. L. B. Oxley,et al.  Shear angle solutions in orthogonal machining , 1962 .

[3]  J. T. Black,et al.  An Evaluation of Chip Separation Criteria for the FEM Simulation of Machining , 1996 .

[4]  G. Boothroyd,et al.  Photographic technique for the determination of metal cutting temperatures , 1961 .

[5]  Albert J. Shih,et al.  Finite Element Simulation of Orthogonal Metal Cutting , 1995 .

[6]  M. E. Merchant.  Mechanics of the Metal Cutting Process. I. Orthogonal Cutting and a Type 2 Chip , 1945 .

[7]  V. Piispanen.  Theory of Formation of Metal Chips , 1948 .

[8]  Hideaki Kudo,et al.  Some new slip-line solutions for two-dimensional steady-state machining , 1965 .

[9]  Kyriakos Komvopoulos,et al.  Finite Element Modeling of Orthogonal Metal Cutting , 1991 .

[10]  Milton C. Shaw.  Some Observations Concerning the Mechanics of Cutting and Grinding , 1993 .

[11]  Y. Shin,et al.  Thermo-mechanical modeling of orthogonal machining process by finite element analysis , 1999 .

[12]  D. Tabor,et al.  Frictional interactions between chip and rake face in continuous chip formation , 1979, Proceedings of the Royal Society of London. A. Mathematical and Physical Sciences.

[13]  P. L. B. Oxley,et al.  The Influence of Rate of Strain-Hardening in Machining: , 1961 .

[14]  J. Hashemi,et al.  Finite element modeling of segmental chip formation in high-speed orthogonal cutting , 1994, Journal of Materials Engineering and Performance.

[15]  D. Lee.  The Effect of Cutting Speed on Chip Formation Under Orthogonal Machining , 1985 .

[16]  W. B. Heginbotham,et al.  Metal Cutting and the Built-Up Nose: , 1961 .

[17]  Albert J. Shih,et al.  Finite element analysis of the rake angle effects in orthogonal metal cutting , 1993 .

[18]  W. B. Palmer,et al.  Mechanics of Orthogonal Machining , 1959 .

[19]  J. Strenkowski,et al.  A Finite Element Model of Orthogonal Metal Cutting , 1985 .

[20]  John S. Strenkowski,et al.  Finite element models of orthogonal cutting with application to single point diamond turning , 1988 .

[21]  S. R. S. Kalpakjian.  Manufacturing Processes for Engineering Materials , 1984 .

[22]  Albert J. Shih,et al.  Experimental and finite element predictions of residual stresses due to orthogonal metal cutting , 1993 .

[23]  J. Strenkowski,et al.  Finite element prediction of chip geometry and tool/workpiece temperature distributions in orthogonal metal cutting , 1990 .

[24]  S. Lin,et al.  A Coupled Finite Element Model of Thermo-Elastic-Plastic Large Deformation for Orthogonal Cutting , 1992 .

[25]  Wei H. Yang,et al.  Analysis of orthogonal metal cutting processes , 1992 .

[26]  Albert J. Shih.  Finite element analysis of orthogonal metal cutting mechanics , 1996 .