Authors
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
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