An Analytical-Thermal Modeling Approach for Predicting Forces, Stresses and Temperatures in Machining With Worn Tools

Abstract

In this paper, predictive modeling of cutting and ploughing forces, stress distributions on tool faces and temperature distributions in the presence of tool flank wear are presented. The analytical and thermal modeling of orthogonal cutting that is introduced in Karpat, Zeren and O¨zel [3] extended for worn tool case in order to study the effect of flank wear on the predictions. Work material constitutive model based formulations of tool forces and stress distributions at tool rake and worn flank faces are utilized in calculating non-uniform heat intensities and heat partition ratios induced by shearing, tool-chip interface friction and tool flank face-workpiece interface contacts. In order to model forces and stress distributions under the flank wear zone, a force model from Waldorf [4] is adapted. Model is tested and validated for temperature and force predictions in machining of AISI 1045 steel and AL 6061-T6 aluminum.