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Cutting edge orthogonal contact-zone analysis using detailed tool shape representation

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Abstract

A new method for numerically controlled (NC)-simulation-based numerical analysis of the tool-workpiece contact area in cutting processes is presented. To gain enhanced knowledge about tool-workpiece interaction, determination of chip thickness, contact length, and resulting cross-section area of the undeformed chip is of major interest. Compared to common simulation approaches, where rotationally symmetrically constructed tool shape is used, the new method uses a detailed three-dimensional tool shape model for an extended and more accurate contact zone analysis. As a corresponding representation of the workpiece and its time-dependent change of shape, a multidexel model is used. To perform contact zone analysis, each cutting element and a multidexel model are intersected in discrete time steps corresponding to the tool rotation. Subsequently, the intersection point of each dexel is mapped on the local coordinate system of the cutting geometry. The parametric cutting geometry allows a direct computation of local cutting depth and contact length for each involved point. Based on the local values of contact length and cross section area of the undeformed chip, the characteristic values for the entire contact zone are calculated and used to predict mechanical loads caused by the cutting process. To demonstrate the application of the novel approach, a prediction of forces in slot milling and drilling of 1.1191 steel (C45EN) is presented.

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Authors and Affiliations

  1. Institute of Production Engineering and Machine Tools, Leibniz Universität Hannover, An der Universität 2, 30823, Garbsen, Germany

    Volker Böß, Daniel Niederwestberg, Christoph Ammermann & Berend Denkena

Authors
  1. Volker Böß
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  2. Daniel Niederwestberg
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  3. Christoph Ammermann
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  4. Berend Denkena
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Correspondence to Daniel Niederwestberg.

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Böß, V., Niederwestberg, D., Ammermann, C. et al. Cutting edge orthogonal contact-zone analysis using detailed tool shape representation. Int J Adv Manuf Technol 75, 1641–1650 (2014). https://doi.org/10.1007/s00170-014-6230-8

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  • DOI: https://doi.org/10.1007/s00170-014-6230-8

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