FEA For Orthogonal Metal Cutting
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Date
2010-03
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Addis Ababa University
Abstract
The aim of this thesis is to investigate the information regarding the influence of the cutting
tool geometry (rake angle) on the main cutting force, the influence of cutting speed on the
main cutting force and on the surface texture of the workpiece , and the influence of feed of
cut on the main cutting force for orthogonal metal cutting operations was investigated.
The effects of the main cutting force on stress and their distribution around the surface
contact of cutting edge of cutter and workpeice by using finite element method (FEM) are
analyzed. As simulation tool, commercial Finite Element Method is used. Simulation is one
of tools that have been used widely in several manufacturing areas and organizations. Using a
valid simulation model gives several benefit and advantages in manufacturing in order to
improve productivity. Separation of chip from the workpiece is achieved either only with
continuous remeshing or by erasing elements according to the damage accumulated. From the
results cutting forces can be estimated. For verification of results several cutting experiments
are performed at different cutting conditions, such as rake angle and feed rate. Results show
that commercial code is able to simulate orthogonal cutting operations within reasonable
limits.
Plain damage model seems not appropriate for separation purposes of machining simulations.
On the other hand, although remeshing gives good results, it leads to the misconception of
crack generation at the tip of the tool. Therefore, a new separation criterion is necessary to
achieve both good physical modeling and prediction of process variables.
Keywords: Finite Element Method, Orthogonal Metal Cutting.
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Mechanical Engineering