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Evaluation of cutting edge K-form factor in milling of 316L stainless steel: a study based on FEM

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Abstract

The objective of this research is to simulate the cutting edge micro-geometry in machining stainless steel (SUS-316L). This paper based on finite element method (FEM) analyzes the cutting mechanism of different cutting edge symmetry geometries (K = 1) and asymmetry geometries (K = 0.5 and K = 2), studied plastic strain and residual stress, Mises stress and distribution of temperature, and also tool-chip contact length and the effective rake angle γeff. By drag finishing prepared three kinds of cutting edge roundness with symmetry (K = 1) and asymmetry (K = 0.5 and K = 2), which is cutting test for verifying the correctness of the model through chip geometry morphology. The simulation results suggest that waterfall tools (K = 0.5) can increase stress strain and peak cutting temperature compared with other cutting edge micro-geometry. At the same time, the trumpet tools (K = 2) also have a great influence on sub-surface and surface stress distribution. Therefore, the cutting edge segment on the flank face Sα has significant the metal cutting process.

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Abbreviations

K :

From-factor

Sγ :

Cutting edge segment on the rake face

Sα :

Cutting edge segment on the flank face

Aγ :

Rake face

Aα :

Flank face

φ :

Apex angle

r ε :

Edge radius of the tool (μm)

A :

plastic equivalent strain in (JC) (MPa)

B :

strain related constant in (JC) (MPa)

C :

strain-rate sensitivity constant in (JC)

m :

thermal softening exponent in (JC)

n :

strain-hardening parameter in (JC)

T m :

melting temperature of the work material (JC)

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Acknowledgements

The authors would like to thank the Guohong Tool System (Wuxi) Co., Ltd for providing the experimental conditions and software simulation, including drag finishing and cutting experimental devices, tools, workpiece materials, and the third wave AdvantEdge software.

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Authors and Affiliations

  1. School of Mechatronics Engineering and Automation, Shanghai University, Shanghai, 200444, China

    Dejin Lv, Xin Yu & Yongguo Wang

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  1. Dejin Lv
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  2. Xin Yu
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Contributions

Dejin Lv: methodology, data curation, formal analysis, writing original draft. Xin Yu: investigation, data curation. Yongguo Wang: supervision, writing — review and editing.

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Correspondence to Yongguo Wang.

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Lv, D., Yu, X. & Wang, Y. Evaluation of cutting edge K-form factor in milling of 316L stainless steel: a study based on FEM. Int J Adv Manuf Technol 128, 5223–5236 (2023). https://doi.org/10.1007/s00170-023-12098-2

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