A finite element analysis of orthogonal machining using different tool edge geometries

This paper summarizes the effects of edge preparation of the cutting tool (round/hone edge and T-land/chamfer edge) upon chip formation, cutting forces, and process variables (temperature, stress, and strain) in orthogonal cutting as determined with finite element method (FEM) simulations. The results obtained from this study provide a fundamental understanding of the process mechanics for cutting with realistic cutting tool edges and may assist in the optimization of tool edge design. The Lagrangian thermo-viscoplastic cutting simulation of 0.2% carbon steel was conducted until the steady chip flow and cutting forces were obtained. The predicted cutting forces and chip geometries for the hone tools with different edge radii were compared with the experimental results given in the literature. Tool temperatures and tool stresses on the tool rake face were predicted while the material flow at the vicinity of the edge radius was characterized by the location of the stagnation point. A similar process model and the relevant analyses were extended to the application of chamfer tools with different chamfer widths and chamfer angles.