Author
Abstract
In this paper, a plane strain Finite Element Method is developed and applied to model and simulate the orthogonal metal cutting of (AISI 1045 St) with continuous chip formation. Seven sets of simulation results for cutting with rake angles (-15o, -10o, -5o, 0o, 5o, 10 o and 15o), are summarized and compared to analyze their effects in the cutting process in steady state condition. Simulation results of the residual stresses below the machined layer are presented and compared with other papers in the literature and showed good agreement.
Simulation results offer an insight into residual stresses through different values of rake angles. Based on simulation results, characteristics of residual stress distribution can be controlled by optimizing the rake angle. The simulated results show that for positive rake angles and position, the zero of maximum effective stress is found to be at (0.04) mm beneath the work piece surface, while for negative rake angles, the position of maximum effective stress is changed to be directly on the workpiece surface.
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