Finite Element Analysis of Orthogonal Machining with Grooved Tool

In metal cutting process, the geometry of the cutting tool insert greatly affects the cutting forces, stress, strain, strain rate and temperature. In this study, chip formation process of the grooved tool Is simulated by finite element method (FEM). The modified Johnson and Cook's plasticity equation was employed to determine the flow stress. Frictional interaction along the tool- chip interface was modeled with shear friction. Orthogonal metal cutting experiments were performed with different cutting feed rates (0.16 and 0.24 mm/rev) to predict the cutting forces. AISI1045 steel was used as a work material and coated carbide was used as cutting tool. The FE simulated cutting forces, shear angle and chip thickness were compared with the experimental results. The deviation between experiment and FEA predicted cutting force was found to range between 2 - 5% and thrust force between 1 8 - 27%. The distribution of effective stress, effective strain, and effective strain rate and temperature were also studied. The results obtained from this study provide a good understanding of the metal cutting process with realistic cutting tool geometry.