Numerical Analysis of Metal Cutting With Chamfered and Blunt Tools

[+] Author and Article Information
M. R. Movahhedy

Department of Mechanical Engineering, Sharif University of Technology, Tehran, Iran

Y. Altintas, M. S. Gadala

Department of Mechanical Engineering, The University of British Columbia, 2324 Main Mall, Vancouver, Canada

J. Manuf. Sci. Eng 124(2), 178-188 (Apr 29, 2002) (11 pages) doi:10.1115/1.1445147 History: Received May 01, 2000; Revised June 01, 2001; Online April 29, 2002
Copyright © 2002 by ASME
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Schematic view of cutting process with a chamfered tool
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Initial and final chip shape in a typical ALE analysis of cutting process
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Velocity field on the chamfered edge of tools with different chamfer angles shows the presence of a stagnated metal zone. From top and left: −10 deg, −25 deg, −35 deg chamfer angles, worn tool of radius 0.075 mm. Velocities are in mm/s.
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Distributions of effective stress (top) and plastic strain rate (bottom) for different chamfer angles
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Distribution of σxx for sharp and chamfered tools of various chamfer angles
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Distribution of σyy for sharp and chamfered tools of various chamfer angles
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Cutting and thrust forces vs. chamfer angle. Numerical predictions are compared with experimental and analytical results of Ren and Altintas 11.
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Temperature distribution in the chip and the tool for the case of −35 deg chamfer angle
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Distributions of (a) σxx, (b) σyy, (c) effective plastic strain rate, and (d) temperature for the worn tool
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Distribution of effective plastic strain rate (left), and temperature (right) for CBN tools at cutting speeds of Vw=240, 600, 1000 m/min, from top to bottom, respectively
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Effect of cutting speed on the cutting and thrust forces. Numerical predictions are compared with experimental and analytical results of Ren and Altintas 11.




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