Analytical Analysis and Determination of Stress Distribution in Tool-chip Contact Area in Orthogonal Machining

The tool-chip contact phenomena in machining process are the important issue for manufacturing researchers to study due to their effects on the tool life, machined surface finish and machining power. In this area, a large number of studies have been carried out in recent decades. Some subjects such as normal and frictional stress distributions, tool wear and tool-and- chip temperature in tool-chip interface have been studied. The thermal contact property of tool and chip in their interface is one of the important subjects in the tool-chip contact research area that has not been completely investigated yet. Stress distribution in tool-chip contact area affects the quantity and distribution of thermal energy transferring from deformation zones in work piece into cutting tool. Thus, in order to investigate the thermal property of tool-chip contact, it is necessary to study the stress distribution in tool-chip contact area. In this paper, the normal stress distribution in tool-chip contact interface is determined by using analytical models. The normal and shear stress distribution analysis results are compared with experimental data given in literature. The analytical results are in agreement with experimental data in most cases. In addition, a concise discussion is brought up in the paper about the factors causing the disagreements between analytical results and experimental data in some materials and cutting conditions. Finally, the normal and shear stress distribution diagrams in tool-chip contact area are calculated for AISI 1045 and AISI 304 steel in various cutting speeds by the proposed model.

Keywords:

Orthogonal cutting , Tool-chip interface , Analytical analysis , Contact area