A finite element investigation on the effects of rake angle, edge radius and friction on the cutting force in orthogonal machining of Aluminum ۶۰۶۱-T۶

This Paper investigates the effects of rake angle, edge radius and friction on the machining force of the Orthogonal cutting of Aluminum ۶۰۶۱-T۶. A ۳D model using finite element ABAQUS/EXPLICIT general code embedding the Johnson cook plastic behavior is presented to simulate continuous chip formation. Furthermore, the Johnson cook damage model is employed to initiate damage and model chip separation. The effect of positive and negative rake angle on machining forces is investigated as well as the effect of edge radius and friction. The simulation shows that increasing the rake angle results in decreasing the cutting force while increasing edge radius and friction intensifies the cutting force.

Keywords:

Orthogonal machining , Cutting force , Rake angle , edge radius , friction , finite element analysis