2D Cutting Model Examples

The cutting tool programs can be used to predict chip thickness and shape, tool forces, pressure distribution on the tool cutting edge, and temperature distributions in the workpiece, chip, and tool. We have used this information for further tool analysis, such as calculating wear rates for carbide and diamond tools based on predicted tool temperatures. Other typical applications include tool design and selection for dry or high speed machining, design of chip control tools, and design of tool coatings for improved tool performance.

The cutting programs take advantage of the power and generality of the finite element technique. General tool geometries can be simulated such as flat, groove, and obstruction-type chip control tools. The models have been used to simulate a variety of workpiece materials, such as steel, stainless steel, aluminum alloys, copper, brass, and polymers. Cutting tools have included high speed steel, diamond, and carbide. These are just typical examples of the workpiece and tool materials that can be simulated.

The following figures show some typical temperature contours predicted with the models for cutting of AISI 1020 steel with carbide inserts. Note that the tool forces, and the chip shape and thickness are also predicted with the models.

Temperature Contour Plot: (Fahrenheit)

Groove type tools:

(2)g651528 result: doc= 0.0065in, rake angle=15, tool nose radius=0.0015in, speed= 80ips

Flat type tool:

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