ELABORATION OF ANALYTICAL THERMO-MECHANICAL CUTTING MODEL MATCHED BY NUMERICAL AND EXPERIMENTAL RESULTS
AbstractThe global aim of this paper is to propose a complete analytical model concerning the material removal. In order to take into account all the aspects of the process, a “phenomena split approach”, based on the assumption that the material removal is the summation of three major contributions, ploughing, spring back and “pure cut” was adopted. This new methodology is developed on the base of experimental tests and industrial experience. In fact the chip is not systematically present. When the chip exists, a part of theoretical layer of the material to be removed is transformed in lateral burrs and elastic compression under the tool tip. In this paper this new approach is presented and the “pure cut” contribution is developed in details. This analytical sub-model of chip formation is calibrated and fitted with a finite element modeling, in order to presents new hypothesis and new formula based on the physics close to the tip of the tool. The chip is considered rigid and uniform, and the regime is supposed stationary. Thermo-mechanical law is applied in shear zones where plastic strain, temperature and strain rate are concentrated. The model takes into account the cutting edge radius too, using an equivalent cutting angle. The friction coefficient at the interface tool-chip is also analytically computed and the present model is considered predictive.