In high speed machining of hard materials, tools with chamfered edge and materials resistant to diffusion wear are commonly used. In this paper, the influence of cutting edge geometry on the chip removal process is studied through numerical simulation of cutting with sharp, chamfered or blunt edges and with carbide and CBN tools. The analysis is based on the use of ALE finite element method for continuous chip formation process. Simulations include cutting with tools of different chamfer angles and cutting speeds. The study shows that a region of trapped material zone is formed under the chamfer and acts as the effective cutting edge of the tool, in accordance with experimental observations. While the chip formation process is not significantly affected by the presence of the chamfer, the cutting forces are increased. The effect of cutting speed on the process is also studied.
Numerical Analysis of Metal Cutting With Chamfered and Blunt Tools
Contributed by the Manufacturing Engineering Division for publication in the JOURNAL OF MANUFACTURING SCIENCE AND ENGINEERING. Manuscript received May 2000; Revised June 2001. Associate Editor: S. G. Kapoor.
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Movahhedy, , M. R., Altintas, , Y., and Gadala, , M. S. (April 29, 2002). "Numerical Analysis of Metal Cutting With Chamfered and Blunt Tools ." ASME. J. Manuf. Sci. Eng. May 2002; 124(2): 178–188. https://doi.org/10.1115/1.1445147
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