A Rigid-Plastic Finite Element Analysis of Micro Cutting.

This paper deals with theoretical and experimental analyses of orthogonal micro cutting process of copper. A method is proposed based on the rigid-plastic FEM (Finite Element Method) to simulate the orthogonal micro cutting process of copper taking into consideration of the roundness of the tool edge. Orthogonal micro cutting experiments of oxygen free copper are carried out within a SEM (Scanning Electron Microscope) employing tools with rounded tool edges. The machinability in the orthogonal micro cutting is discussed from the viewpoints of the chip formation, the cutting forces and the distribution of the stress in the workpiece. Emphasis is given in particular to the effect of the roundness of the tool edge on the micro cutting process of copper.