Estimation of normal pressure at tool-chip interface based on finite element method (FEM)‎

Abstract EN

The main objective of this study is to investigate the effect of rake angle on normal pressure distribution at tool-chip interface region, in order to gain better understanding of the rake angle effects in orthogonal cutting with continuous chip formation.

The effect of normal pressure at tool-chip interface for (AISI1045 St) has been studied for cutting tools having various rake angles, which are modeled and simulated.

Special FEM codes are applied, the first code is : ( MSC FEA/PATRAN/2004), used for preprocessing and postprocessing, while the second one is (MSC FEA / DYTRAN / 2004), used for the analysis stage.

Finite Element model sets for steady state orthogonal cutting are presented.

The model simulates chip formation process in detail.

The modeling and simulation process is based on certain criteria called "Johnson-Cook" constitutive model for predicting dynamic material behavior, so the flow stress of the chip is taken as a function of strain hardening, strain rate and temperature.

It is concluded from the simulated results, that the normal pressure is minimum when the rake angle is (5°), while the normal pressure is maximum when the rake angle is (-15°).

Pressure distribution and behavior at this region are studied in detail.

The results are compared with many relevant papers published in the literature and showed a good agreement with the modeled results.