An analysis of cutting under different rake angles using the finite element method

Abstract

The elastic–plastic finite element method is developed in this study to investigate the effect of the tool rake angle on the chip and the machined workpiece during the precision cutting process. Cutting simulations were conducted under a variety of tool rake angles to explore the effect of tool rake angle on cutting force, the geometric shapes of the chip, the equivalent stress distribution, the residual stress and the surface of the machined workpiece. The findings indicate that an increase in the tool rake angle leads to the following: a decrease in the cutting force required during machining; a smoother chip contour; a smaller difference between the chip thickness and the undeformed chip thickness; a decrease in the equivalent stress distribution; and a less pronounced curvature phenomenon at the initial cutting end of the machined workpiece. Further, the results also show that as the tool rake angle increases from 5 to 15°, the changes in the above-mentioned physical phenomena are more pronounced. In contrast, the increase of tool rake angle from 15 to 20° hardly brought about any changes to these physical phenomena. Therefore, to reach the goal of lowering the above requirements such as the cutting force so as to extend tool life, it is recommended that a tool rake angle of 15° instead of 20° be adopted for cutting.