Analysis of the Cutting Mechanics Under the Influence of Worn Tool Geometry

In machining, wear formation changes the effective geometry of the cutting edge which directly influences the mechanics of cutting. Analysis of the cutting mechanics and determination of the corresponding machining performance with a worn edge is of significant importance in terms of tool design, surface integrity, and process optimization. In the present study the effective geometry of the cutting edge was analyzed prior to cut by employing the circular regression method. Experimental cutting tests were performed and the effect of cutting time on the wear progression was investigated at several time intervals. The worn edge geometries were used to build the Arbitrary Lagrangian - Eulerian finite element cutting models in ABAQUS/Explicit. The models were validated by comparing the simulation results with the experimental findings of machining forces and chip thicknesses. The validated models were then employed to investigate the effect of wear geometry on the contact stresses, plastic deformation, and temperature distributions in the cutting zone.