Abstract

Observations are made regarding the influence of cutting speed and friction on cutting force by way of finite element modeling. Simulations are validated by comparison of cutting forces and chip morphologies for the A16061-T6. Analysis of cutting forces over a wide range of cutting conditions suggests an important role of the secondary shear zone in the decrease of cutting force as a function of speed, even well into what is considered to be the adiabatic machining regime. The proposition is supported by a decrease in chip thickness and significant increase in temperature at the tool-chip interface as the speed is increased. Temperatures in the primary shear zone rise only modestly and cannot account for the change in cutting force. Furthermore, the effect contributes to the nonlinear increase of forces with respect to feed as opposed to a plowing force by the cutting edge radius.

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