Finite Element Analysis of the Rake Angle Effects on Residual Stresses in a Machined Layer
Engineering and Technology Journal,
2007, Volume 25, Issue 1, Pages 36-48
AbstractIn 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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