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Development and validation of a new friction model for cutting processes

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Abstract

The friction model in the tool-chip interface has significant influences on predicting chip forms, cutting forces, and cutting tool temperatures, when simulating the chip formation using the finite element method. In this paper, the friction behavior in the tool-chip interface was investigated experimentally and numerically under cutting conditions. The friction tests were performed with different workpiece materials (AISI 1045 and Direct Aged Inconel 718) in combination with uncoated and coated cemented carbide cutting tools. Various process normal forces were applied to achieve different contact pressures. The experimental results showed strong influences of relative speeds, contact pressures, and contact temperatures on apparent friction coefficients. In addition, an advanced friction model was proposed and validated with 3D FE-simulations of the friction test.

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  • 30 April 2020

    The authors wish to thank the German Research Foundation (DFG) for funding the research within the project "Modelling of broaching processes by multi-scale discretization" (KL500/159-1).

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Funding

The study is supported by the German Research Foundation (DFG) for the funding of the depicted research within the project. The authors wish to thank the German Research Foundation (DFG) for funding the depicted research within the project.

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Authors and Affiliations

  1. Laboratory for Machine Tools and Production Engineering (WZL) of RWTH Aachen University, Campus-Boulevard 30, 52074, Aachen, Germany

    Bingxiao Peng, Thomas Bergs, Daniel Schraknepper, Thobias Smigielski & Fritz Klocke

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  1. Bingxiao Peng
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  2. Thomas Bergs
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  3. Daniel Schraknepper
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  4. Thobias Smigielski
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  5. Fritz Klocke
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Correspondence to Bingxiao Peng.

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Peng, B., Bergs, T., Schraknepper, D. et al. Development and validation of a new friction model for cutting processes. Int J Adv Manuf Technol 107, 4357–4369 (2020). https://doi.org/10.1007/s00170-019-04709-8

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