Abstract
Cutting is the primary method of material removal, and the quality of machined parts depends on the geometry of cutting tools. In this paper, a new cutting force coefficient model is established, revealing the influence of cutting-edge radius on the cutting process. The effects of cutting-edge radius on the shear angle and cutting force components are analyzed by finite element simulations. A series of simulations is conducted, and the results show that with increased cutting-edge radius, the shear angle decreases nonlinearly, and the cutting force increases gradually. Additionally, the growth rate of the feed force caused by increasing the cutting-edge radius is higher than that of the tangential force. Furthermore, the stress concentration area of the machined surface extends from the surface to the subsurface as the cutting-edge radius increases. The results of this research show that changing the cutting edge affects the cutting force component, shear angle, and stress concentration range during the cutting process. These results provide a theoretical reference for predicting the residual stress in parts.
Highlights
Cutting machining is a common manufacturing method that is widely used in industrial applications, such as the precision machining of optical parts
This section studies the effects of Cutting-edge radius (CER) on shear angle, cutting force, and stress concentration depth
CER is the key parameter of the geometry of the cutting tool that cannot be ignored in micromachining
Summary
Cutting machining is a common manufacturing method that is widely used in industrial applications, such as the precision machining of optical parts. In micron-scale cutting, the undeformed chip thickness is close to the CER, and the CER is a vital parameter that cannot be ignored. With the rapid development of computer technology, Woon et al [13,14] used the finite element method to study the relationship between chip formation and CER. Lai et al [17] considered that CER changes the rake angle of the tool, and the undeformed chip thickness is directly proportional to the CER. This paper proposes a finite element analysis model to analyze the evolution of the shear angle and explore the variational principle of cutting force components with CER; it is not the magnitude of cutting force and stress of existing theories, but a new insight of evolution. This study provides a new theoretical reference for controlling the surface integrity of parts
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