A new thermomechanical model of cutting applied to turning operations. Part II. Parametric study

Abstract

In Part I of this work, Molinari and Moufki [Int. J. Mach. Tools Manufact., this issue], an analytical model of three-dimensional cutting is developed for turning processes. To analyse the influences of cutting edge geometry on the chip formation process, global effects such as the chip flow direction and the cutting forces, and local effects such as the temperature distribution and the surface contact at the rake face have been investigated. In order to accede to local parameters, the engaged part in cutting of the rounded nose is decomposed into a set of cutting edge elements. Thus each elementary chip, produced by a straight cutting edge element, is obtained from an oblique cutting process defined by the corresponding undeformed chip section and the local cutting angles. The present approach takes into account the fact that for each cutting edge element the local chip flow is imposed by the global chip movement. The material characteristics such as strain rate sensitivity, strain hardening and thermal softening, the thermomechanical coupling and the inertia effects are considered in the modelling. A detailed parametric study is provided in this paper in order to analyse the effects of cutting speed, depth of cut, feed, nose radius and cutting angles on cutting forces, global chip flow direction and temperature distribution at the rake face. The influence of friction at the tool–chip interface is also discussed.