Analysis of the effect of tool geometry on the shear angle in metal cutting

Abstract

Finite element analysis based techniques are available to simulate cutting processes and offer several advantages including prediction of tool forces, distribution of stresses and temperatures, estimation of tool wear and residual stresses on machined surfaces, optimization of cutting tool geometry and cutting conditions. However, workpiece material flow stress and friction characteristics at cutting zones are not always available. This paper utilizes a simple metal cutting model and shows running results. The friction model is based on estimation of the normal stress distribution over the rake face. The changing of shear angle and cutting forces in cutting of different workpiece material in the beginning of cutting is shown in this paper.