Abstract:
The tool wear found in machining processes represents main obstacle for
machinability due to its detrimental effects on surface roughness, material removal
rate and machining economy. A nonlinear thermomechanical finite element model
was developed to simulate the tool chip interaction. This model predicts not only
the chip morphology and chip flow direction, cutting forces values, stress
distribution, but also can use to predict tool wear. Furthermore, the effect of elastic
deformation (spring back) and the thermal effect have been considered in the model.
Cutting force was predicted and compared with the conducted experimental work.
Dry turning operation was carried out on low carbon steel using carbide tool. The
tool/workpiece interface stress on flank face was calculated and compared with the
FEM. Predicted results show good correlation with the FEM. FE model was
verified experimentally by measuring the cutting force. The friction on the flank
face and spring back concentrates the stress on the flank face.
