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

Tawfiq, Maan Aabid; Shahab, Suha Kareem

doi:10.30684/etj.25.4.5

	A Finite Element Analysis of Orthogonal Machining Using Different Tool Edge Geometries
Engineering and Technology Journal
Volume 25, Issue 4, 2007, Pages 569-583 PDF (224.96 K)
DOI: 10.30684/etj.25.4.5
Authors
Maan Aabid Tawfiq; Suha Kareem Shahab
Abstract
This paper summarizes the effects of edge preparation of the cutting tool in orthogonal cutting on the following variables: stress distributions at the tool rake face, cutting forces and tool-chip contact length. The Finite Element Method (FEM) is selected using the ANSYS /V4.5 code. Six models of cutting tools have been suggested having edge radii of (0.01, 0.05, 0.1, 0.15, 0.2, and 0.25) mm. The results obtained provide a fundamental understanding of the process mechanics for cutting with realistic cutting tool edge radius in order to assist in the optimization of tool edge design. The results show that the optimum edge radius from the six simulated models is (0.05) mm; this edge radius gives minimum value of effective stress. The results show also that the optimum edge radius that shows minimum tangential cutting and feed forces is (0.01) mm. The results investigated that the tool-chip contact length is increased, until reaching maximum value of (2.4) mm at (r=0.15mm), and minimum value of (0.75) mm at (r=0.01mm). The maximum relative difference between simulated results of this work and other previous paper results is (2% - 17%) for the tool effective stresses, (5%) for the tangential force, and (11%) for the feed force.
Keywords
FEM; edge radius; orthogonal machining

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