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A novel finite element investigation of cutting force in orthogonal cutting considering plough mechanism with rounded edge tool

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Abstract

The plough phenomenon generated by the micro-scale cutting edge plays an important role in tool wear, chip formation and surface integrity. In this study, the plough mechanism in orthogonal cutting with rounded edge tool is investigated by finite element method (FEM). The separation line is developed to determine the contact behavior between rounded edge tool and workpiece. Especially, the workpiece material flow is explored in detail with the definition of separation line. Three contact regions are identified and three frictional force components along the cutting edge are proposed. Then, the Johnson-Cook constitutive model and Johnson-Cook ductile damage criteria are used to describe the plastic deformation and damage mechanics in the cutting simulation with ABAQUS. A developed method based on finite element analysis is proposed to identify three force components individually, including separation line determination based on nodal displacement and three contact region determination with partition function. The accuracy and correctness of the novel FEM model are validated by a series of orthogonal cutting processes. Moreover, the nonlinearly increase relationship between specific cutting energy and edge radius is discussed considering size effect.

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Funding

This work is partially supported by the National Natural Science Foundation of China (51705385, 51975237) and The Fundamental Research Funds for the Central Universities (2019-YB-019).

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Authors and Affiliations

  1. Hubei Digital Manufacturing Key Laboratory, School of Mechanical and Electronic Engineering, Wuhan University of Technology, Wuhan, China

    Weiwei Zhang & Kejia Zhuang

  2. Wuxi Research Institute of Huazhong University of Science and Technology, Wuxi, China

    Donglin Pu

  3. Technology Center, Wuxi Turbine Blade Co., Ltd., Wuxi, China

    Donglin Pu

Authors
  1. Weiwei Zhang
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  2. Kejia Zhuang
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  3. Donglin Pu
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Correspondence to Kejia Zhuang.

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Zhang, W., Zhuang, K. & Pu, D. A novel finite element investigation of cutting force in orthogonal cutting considering plough mechanism with rounded edge tool. Int J Adv Manuf Technol 108, 3323–3334 (2020). https://doi.org/10.1007/s00170-020-05547-9

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  • DOI: https://doi.org/10.1007/s00170-020-05547-9

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