Analytical modelling of material removal process in the case of orthogonal cutting and worn tools

Abstract

Analytical methods of material removal are usually researched because they are very practical to use, but those methods do not take into account all the aspects of the contact between the work material and the tool. In particular elastoplastic phenomena under the tool are usually not considered, which is pertinent for small cutting edge radius but not for bigger ones (worn tools). In order to take into account all the aspects of the material removal, as chip formation, elastoplastic phenomena under the tool and the spring back at the rear, a 'split approach and composition', is adopted. It is based on the assumption that the material removal is the summation of the cited contributions. The present methodology is applied on orthogonal cutting and is based on thermomechanical computation. All the deformations are concentrated in shear zones, and then it is possible to compute forces, strains and temperatures during tool action, with a good accuracy, compared to experimental results.