Finite Element Analysis of Orthogonal Cutting With Blunt-Edge Tool

Abstract A finite element model is developed for the simulation of orthogonal cutting of ductile material with blunt-edge tools. The model assumes the machining process as a quasi-static process, is capable of performing the coupled thermal-mechanical analysis, and adopts the continuous remeshing techniques. Based on this model, as well as the material property data of a low-carbon steel obtained from previous researches, orthogonal cutting process with blunt-edge tools is thoroughly analyzed. The analysis focuses on strain and stress distributions, deformation zones, chip flow characteristics, and cutting forces with the variation of process parameters such as uncut chip thickness and edge radius. Due to the computational load, thermal effect is not incorporated in the analysis. Some critical issues, such as chip stagnation point and recovery after ploughing, are investigated. It is found that uncut chip thickness and edge radius have some important influences on the strain and stress values, the shapes of deformation zones, and the cutting forces. The chip stagnation point has a consistent position on the cutting edge when the ratio of uncut chip thickness to edge radius is between 0.7 to 5. The recovery from ploughing is not significant. The intent of the study is to improve the basic understanding of the cutting process with blunt-edge tool for more precise modeling in the future.