Abstract
A thermoelastoplastic analysis is made to study the surface waviness of orthogonal machine cutting. As a workpiece experiences heavy cutting, chips are formed incrementally in a steady fashion leaving a sinusoidal wavy surface as evidence of the varying thickness of the uncut chips. The finite difference method is applied to determine the temperature distribution in the chip and tool while a large deformation thermoelastoplastic finite element analysis is made to simulate the wave removing process whereby the wavy surface is modelled by saw-tooth shaped meshes. Determined are the chip geometry, residual stresses in the machined surface, temperature distributions in the chip and tool forces. The cutting forces are also calculated and they agree well with the test results.
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