Numerical Analysis of Influence of Cutting Edge Radius on the Minimum Thickness of the Machined Layer

Abstract

Possibilities of miniaturization of products are constantly increasing and create numerous technological challenges at the same time. One of the important aspects of the machining process, which is the essence of this work, is the geometry of the cutting tool. This work aims to investigate the influence of three different radius of cutting edge on the minimum thickness of machined layer. The phenomena on a typical incremental step were described using a step-by-step incremental procedure, with an updated Lagrangian formulation. The machining process is considered as geometrical and physical non-linear initial and boundary problem. The finite element method (FEM) and the dynamic explicit method (DEM) were used to obtain the solution. The application was developed in the ANSYS/LS-DYNA system which makes possible a complex time analysis of the physical phenomena: states of displacements, strains and stresses. Numerical computations of the strain have been conducted with the use of methodology which requires a proper definition of the contact zone, without the necessity to introduce boundary conditions. Examples of calculations are presented and show what the depth of cut at a given radius of cutting edge allows achieving a minimum thickness of cutting.