FEM INVESTIGATION FOR ORTHOGONAL CUTTING PROCESS WITH GROOVED TOOLS–TECHNICAL COMMUNICATION

Rigid-visco-plastic finite element models are used to simulate the chip formation and cracking in the turning processes with grooved tools. The Johnson-Cook constitutive equation and Johnson-Cook damage model, which are appropriate for high-speed machining, are assumed for the workpiece material properties. Thermal effects in cutting are considered. The tool material is considered as rigid, but heat-conducting, with the properties of tool material H11. The calculated chip back-flow angle, curling radius and thickness are analyzed as three typical chip shape parameters. The effects of land length and second rake angle of the grooved tool on chip formation, cracking and temperature are discussed. Some simulation results are compared with other published analytical and experimental results.

[1]  P. Zeng,et al.  Three-dimensional thermo-elastic-plastic coupled FEM simulations for metal oblique cutting processes , 2005 .

[2]  Vahid Kalhori,et al.  Modelling and simulation of mechanical cutting , 2001 .

[3]  Liangchi Zhang,et al.  On the separation criteria in the simulation of orthogonal metal cutting using the finite element method , 1999 .

[4]  G. R. Johnson,et al.  Fracture characteristics of three metals subjected to various strains, strain rates, temperatures and pressures , 1985 .

[5]  I. Jawahir,et al.  Finite element modeling of residual stresses in machining induced by cutting using a tool with finite edge radius , 2005 .

[6]  T. Özel,et al.  Determination of work material flow stress and friction for FEA of machining using orthogonal cutting tests , 2004 .

[7]  C. A. van Luttervelt,et al.  Recent Developments in Chip Control Research and Applications , 1993 .

[8]  S. M. Athavale,et al.  A Partially Constrained Eulerian Orthogonal Cutting Model for Chip Control Tools , 1997 .

[9]  P. X. Li,et al.  Predictability of tool failure modes in turning with complex grooved tools using the equivalent toolface (ET) model , 2000 .

[10]  T. Shi,et al.  Modeling chip formation with grooved tools , 1993 .

[11]  P.L.B. Oxley,et al.  A universal slip-line model with non-unique solutions for machining with curled chip formation and a restricted contact tool , 2001 .

[12]  Gang Fang,et al.  Effects of Tool Geometrical Parameters on the Chip Formation and Cutting Force in Orthogonal Cutting , 2004 .

[13]  W. Grzesik,et al.  An energy approach to chip-breaking when machining with grooved tool inserts , 1997 .

[14]  Richard E. DeVor,et al.  Modeling of turning process cutting forces for grooved tools , 2002 .

[15]  Toshiyuki Obikawa,et al.  Chip breaking analysis from the viewpoint of the optimum cutting tool geometry design , 1996 .

[16]  Richard E. DeVor,et al.  Mechanistic Force Models for Chip Control Tools , 1999 .

[17]  T. Wierzbicki,et al.  Calibration and evaluation of seven fracture models , 2005 .

[18]  M. Elbestawi,et al.  Chip formation during microscale cutting of a medium carbon steel , 2006 .