Abstract
In this paper, a finite element method for predicting the temperature and the stress distributions in micro-machining is presented. The work material is oxygen-free-high-conductivity copper (OFHC copper) and its flow stress is taken as a function of strain, strain rate and temperature in order to reflect realistic behavior in machining process. From the simulation, a lot of information on the micro-machining process can be obtained; cutting force, cutting temperature, chip shape, distributions of temperature and stress, etc. The calculated cutting force is found to agree with the experiment result with the consideration of friction characteristics on the chip–tool contact surface. Because of considering the tool edge radius, this cutting model using the finite element method can analyze micro-machining with a very small depth of cut, almost the same size of tool edge radius, and can observe the `size effect' characteristic. Also, the effects of temperature and friction on micro-machining are investigated.
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