Finite element investigations for chip scraping during orthogonal cutting process with micro-textured tools

Compared with the conventional tool (CT), the micro-textured tool (MTT) has the advantages of reducing cutting forces, lowering cutting temperatures and inhibiting tool wear. However, the chip scraping phenomenon generated in the cutting process has negative effects and degrades cutting performance when using the MTT with grooves perpendicular to the cutting edge. Due to the difficulty in observing and characterizing chip scraping in situ by experiments, its mechanism and influence on specific cutting forces and tool wear are not fully understood. To this end, finite element (FE) method is employed for simulating the cutting process with MTT. The simulation model is validated by comparing the predicted and measured specific cutting forces. The average prediction error of specific cutting and feed forces is 12.4 % and 18.8 %, respectively. The simulation results indicate that chip scraping mainly results from the discontinuity, non-uniformity and high contact stress state of the tool-chip interface. The minimum specific cutting force is achieved when the advantages of micro-texture and the chip scraping effects are balanced. The MTT rake face wear is subdivided into a severe and a sliding wear zone. This partition characteristic is closely associated with normal contact stress and temperature distributions. The work in this paper contributes to improving the understanding of chip scraping, optimizing micro-texture and cutting parameters, and promoting MTT applications in the manufacturing industry.