Research Papers

Finite Element-Based Study of the Mechanics of Microgroove Cutting

[+] Author and Article Information
Keith A. Bourne

e-mail: kbourne200@gmail.com

Shiv G. Kapoor

Grayce Wicall Gauthier Chair in Mechanical Science and Engineering
e-mail: sgkapoor@illinois.edu

Richard E. DeVor

College of Engineering Distinguished
Professor of Manufacturing
Department of Mechanical Science and Engineering
University of Illinois at Urbana-Champaign,
Urbana, IL 61801

1Corresponding author.

Contributed by the Manufacturing Engineering Division of ASME for publication in the Journal of Manufacturing Science and Engineering. Manuscript received May 18, 2011; final manuscript received February 11, 2013; published online May 27, 2013. Assoc. Editor: Tony Schmitz.

J. Manuf. Sci. Eng 135(3), 031017 (May 27, 2013) (8 pages) Paper No: MANU-11-1182; doi: 10.1115/1.4024154 History: Received May 18, 2011; Revised February 11, 2013

In an earlier paper, a high-speed microgroove cutting process that makes use of a flexible single-point cutting tool was presented. In this paper, 3D finite element modeling of this cutting process is used to better understand process mechanics. The development of the model, including parameter estimation and validation, is described. Validation experiments show that on average the model predicts side burr height to within 2.8%, chip curl radius to within 4.1%, and chip thickness to within 25.4%. The model is used to examine chip formation, side burr formation, and exit burr formation. Side burr formation is shown to primarily occur ahead of a tool and is caused by expansion of material compressed after starting to flow around a tool rather than becoming part of a chip. Exit burr formation is shown to occur when a thin membrane of material forms ahead of a tool and splits into two side segments and one bottom segment as the tool exits a workpiece.

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Fig. 1

Side burrs on side of groove cross-section

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Fig. 2

Exit burrs at groove intersections

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Fig. 5

Overall model geometry

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Fig. 6

Simulated tool (a) and gap under tool (b)

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Fig. 7

Material failure regions

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Fig. 8

Material shear strength at rake face

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Fig. 9

Symmetry plane stress (left) and strain (right)

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Fig. 10

Surface and subsurface stresses and strains

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Fig. 11

Flow of material around tool

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Fig. 12

Side burr formation events

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Fig. 13

Exit burr formation events




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