Investigation of size-effects in machining with geometrically defined cutting edges

M. Weber*, T. Hochrainer, P. Gumbsch, H. Autenrieth, L. Delonnoy, V. Schulze, D. Löhe, J. Kotschenreuther, J. Fleischer

*Corresponding author for this work

Research output: Contribution to journalArticle

Abstract

The miniaturization of cutting processes shows process specific size-effects like the exponential increase of the specific cutting force kc with decreasing depth of cut h. Experiments were carried out in an orthogonal turning process. The influence of different process parameters on the results was investigated separately to identify process specific size-effects. Two materials were studied: a normalized steel AISI 1045 and an annealed AISI O2. To complement the experiments, parameter variations were performed in two-dimensional, thermo-mechanically coupled finite element simulations using a rate-dependent material model and analyzed by similarity mechanics. The influence of rounded cutting-edges on the chip formation process and the plastic deformation of the generated surface were determined numerically. The complex physical effects in micro-cutting were analyzed successfully by finite element simulations and compared to experiments.

Original languageEnglish
Pages (from-to)447-473
Number of pages27
JournalMachining Science and Technology
Volume11
Issue number4
DOIs
Publication statusPublished - Oct 2007

Keywords

  • Finite element simulation
  • Machining
  • Micro-cutting
  • Similarity mechanics
  • Size-effect
  • Specific cutting force

ASJC Scopus subject areas

  • Industrial and Manufacturing Engineering
  • Mechanical Engineering
  • Materials Science(all)

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