Modeling of the minimum cutting thickness in micro cutting with consideration of the friction around the cutting zone

doi:10.1007/s11465-019-0561-y

Front. Mech. Eng.

2020, Vol. 15

Issue (1) : 81-88 https://doi.org/10.1007/s11465-019-0561-y

RESEARCH ARTICLE

Modeling of the minimum cutting thickness in micro cutting with consideration of the friction around the cutting zone

Tianfeng ZHOU¹(

), Ying WANG², Benshuai RUAN², Zhiqiang LIANG¹, Xibin WANG¹

¹. Key Laboratory of Fundamental Science for Advanced Machining, Beijing Institute of Technology, Beijing 100081, China
². School of Mechanical Engineering, Beijing Institute of Technology, Beijing 100081, China

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Abstract

Friction modeling between the tool and the workpiece plays an important role in predicting the minimum cutting thickness during TC4 micro machining and finite element method (FEM) cutting simulation. In this study, a new three-region friction modeling is proposed to illustrate the material flow mechanism around the friction zone in micro cutting; estimate the stress distributions on the rake, edge, and clearance faces of the tool; and predict the stagnation point location and the minimum cutting thickness. The friction modeling is established by determining the distribution of normal and shear stress. Then, it is applied to calculate the stagnation point location on the edge face and predict the minimum cutting thickness. The stagnation point and the minimum cutting thickness are also observed and illustrated in the FEM simulation. Micro cutting experiments are conducted to validate the accuracy of the friction and the minimum cutting thickness modeling. Comparison results show that the proposed friction model illustrates the relationship between the normal and sheer stress on the tool surface, thereby validating the modeling method of the minimum cutting thickness in micro cutting.

Keywords tool friction minimum cutting thickness finite element method tool edge radius micro cutting

Corresponding Author(s): Tianfeng ZHOU

Just Accepted Date: 19 November 2019 Online First Date: 20 December 2019 Issue Date: 21 February 2020

Cite this article:

Tianfeng ZHOU,Ying WANG,Benshuai RUAN, et al. Modeling of the minimum cutting thickness in micro cutting with consideration of the friction around the cutting zone[J]. Front. Mech. Eng., 2020, 15(1): 81-88.

URL:

https://academic.hep.com.cn/fme/EN/10.1007/s11465-019-0561-y
https://academic.hep.com.cn/fme/EN/Y2020/V15/I1/81

Fig.1 Zoerv’s model of the normal and shear stress distribution on the rake face [⁸].

Fig.2 Material flow around the cutting zone.

Fig.3 Stress distributions around the cutting zone.

Fig.4 (a) Normal stress and (b) shear stress on the rake face and clearance face.

Fig.5 Stress distributions in Region III: (a) Normal stress distribution; (b) shear stress distribution.

Fig.6 Illustration of the edge face.

Fig.7 Stress distribution in cutting process: (a) h=0.5r_n, (b) h=r_n, and (c) h=2r_n.

Tab.1 Chemical composition of titanium alloy TC4

Tab.2 Physical and mechanical properties of titanium alloy TC4

Fig.8 Stagnation angle at different rake angles: (a) g₁=–5°, (b) g₁=0°, (c) g₁=3°, and (d) g₁=5°.

Fig.9 Stagnation angle at different clearance angles: (a) g₂=0°, (b) g₂=5°, (c) g₂=8°, and (d) g₂=10°.

Fig.10 Theoretical and simulation values of the stagnation angle at (a) different rake angles and (b) different clearance angles.

Fig.11 Stagnation angle at different tool edge radii: (a) 0.02 mm, (b) 0.05 mm, (c) 0.07 mm, and (d) 0.1 mm.

Fig.12 Illustration of FEM model of micro cutting.

Fig.13 Simulations of the force variation at different fake angles: (a) g₁=–5°, (b) g₁=0°, and (c) g₁=5°.

Fig.14 Experimental setup of micro cutting.

Fig.15 Experimental cutting forces at different fake angles: (a) g₁=–5°, (b) g₁=0°, and (c) g₁=5°.

Fig.16 Experimental and simulation values of the minimum cutting thickness at different rake angles.

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