A Finite Element Analysis of Orthogonal Machining Using Different Tool Edge Geometries

Abstract

This paper summarizes the effects of edge preparation of the cutting tool inorthogonal cutting on the following variables: stress distributions at the toolrake face, cutting forces and tool-chip contact length. The Finite ElementMethod (FEM) is selected using the ANSYS /V4.5 code. Six models of cuttingtools have been suggested having edge radii of (0.01, 0.05, 0.1, 0.15, 0.2, and0.25) mm. The results obtained provide a fundamental understanding of theprocess mechanics for cutting with realistic cutting tool edge radius in order toassist in the optimization of tool edge design. The results show that theoptimum edge radius from the six simulated models is (0.05) mm; this edgeradius gives minimum value of effective stress. The results show also that theoptimum edge radius that shows minimum tangential cutting and feed forcesis (0.01) mm. The results investigated that the tool-chip contact length isincreased, until reaching maximum value of (2.4) mm at (r=0.15mm), andminimum value of (0.75) mm at (r=0.01mm). The maximum relativedifference between simulated results of this work and other previous paperresults is (2% - 17%) for the tool effective stresses, (5%) for the tangentialforce, and (11%) for the feed force.

Keywords

• fem
• edge radius
• orthogonal machining