Title: Analytical modelling of material removal process in the case of orthogonal cutting and worn tools

Authors: Ferdinando Salvatore; Tarek Mabrouki; Hédi Hamdi

Addresses: ENISE, LTDS, UMR CNRS 5513, University of Lyon, 58 Rue Jean Parot, 42023 Saint-Etienne, France ' ENIT, University of El Manar, BP 37, Le Belvedere, 1002 Tunis, Tunisia ' ENISE, LTDS, UMR CNRS 5513, University of Lyon, 58 Rue Jean Parot, 42023 Saint-Etienne, France

Abstract: Analytical methods of material removal are usually researched because they are very practical to use, but those methods do not take into account all the aspects of the contact between the work material and the tool. In particular elastoplastic phenomena under the tool are usually not considered, which is pertinent for small cutting edge radius but not for bigger ones (worn tools). In order to take into account all the aspects of the material removal, as chip formation, elastoplastic phenomena under the tool and the spring back at the rear, a 'split approach and composition', is adopted. It is based on the assumption that the material removal is the summation of the cited contributions. The present methodology is applied on orthogonal cutting and is based on thermomechanical computation. All the deformations are concentrated in shear zones, and then it is possible to compute forces, strains and temperatures during tool action, with a good accuracy, compared to experimental results.

Keywords: worn tool; orthogonal cutting; analytical modelling; plowing; spring back; burr.

DOI: 10.1504/IJMMM.2017.088897

International Journal of Machining and Machinability of Materials, 2017 Vol.19 No.6, pp.570 - 586

Received: 19 Apr 2016
Accepted: 29 Oct 2016
Published online: 02 Jan 2018 *

Full-text access for editors Full-text access for subscribers Purchase this article Comment on this article