An application of the finite element method to the prediction of cutting tool performance

Abstract

In metal cutting tools the are close to the tool point is the single most important region and conditions at the tool point must be carefully examined if improvements in tool performance, through changes in tool design and material, are to be achieved. The paper describes an analysis of cutting tool performance through a determination of the stress distribution within, and at the boundaries of, the tool wedge. The stressanalysis was based on a two-dimensional model as encountered in orthogonal cutting, using a range of cutting geometries including tools with double rake angles. A finite element technique was employed which can be effectively utilised in the solution of metal cutting problems once the boundary conditions have been established. The results presented demonstrate the significance of the chosen boundary conditions to the analysis of metal cutting. Finally it is argued that the deformation of the cutting edge, especially at the clearance face under the stress field set up in the tool, may well be a determining factor in establishing tool life as based on the flank wear criterion.