Tool-edge geometry effects in semi-to-finish cut machining operations on subsurface integrity and tool thermo-mechanical loadings: A coupled damage-fracture energy based finite element approach

Abstract

Present work put forwards a numerical approach to quantify the effects of honed-edge and chamfered-edge tools on residual stresses and end-burr generation while performing semi-to-finish cut machining operations. Maximum stresses and temperatures experienced by tools are computed to predict tool wear intensity at its various sections. Furthermore, the impact of tool edge geometry on fracture and the size of the material damage zone ahead of the tool tip has also been detailed. Chip formation, its evolution and separation have been realized using a coupled damage-fracture energy model considering coupled temperature-displacement simulations in two steps modeling strategy: cutting step and stress relaxation and cooling step. A numerical model has been validated with previous experimental results of chip morphology and cutting forces when machining was performed under similar cutting conditions and tool geometrical profile.

Keywords:

• Damage and fracture in machining
• finite element machining simulation
• machining induced residual stresses
• end-burr
• tool-edge preparation