Investigation of the effects of tool geometry on thecutting force in orthogonal machining of AISI-۱۰۴۵using FE Simulation

In this paper the effects of rake angle and edge radius on the machining force of theOrthogonal cutting of AISI-۱۰۴۵ medium carbon steel is explored. A ۳D model using finiteelement ABAQUS/EXPLICIT general code embedding the Johnson cook plastic behavior ispresented to simulate continuous chip formation. Furthermore, the Johnson cook damagemodel is employed to initiate damage and model chip separation. The FE model is thenverified using well established empirical calculations. Using the FE simulation, the effect ofpositive and negative rake angle on machining forces is investigated as well as the effect ofedge radius and friction. The simulation shows that increasing the rake angle results indecreasing the cutting force while increasing edge radius and friction intensifies the cuttingforce.

Keywords:

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