Finite element analysis of chip breaker geometry in turning process

Abstract

This article applied the rigid-plastic finite element software, DEFORM TM -3D, to investigate the cutting plastic deformation behavior of 6061 aluminum alloy. The main design contained a variety of different geometric types of chip breakers for turning tools. There were three kinds of geometries for chip breakers in our design: the first one is an ordinary cutting tools provided without chip breaker, the second one is a squared concave contour, and the last one is an elliptical concave contour. For the purposes of analyzing the equivalent stress, strain, temperature, and wear of cutting tools after machining, a series of simulations were performed according to the three different geometric chip breaker designs that operated under the same turning conditions. The results of simulation analysis could assist the engineers to confirm the applicability of finite element method for cutting 6061 aluminum alloy. The article found that the squared-type chip breaker generated the maximum wear at the chip breaker area, and the elliptic chip breaker induced homogeneous wear at the tip area.

A review on cutting tool technology in machining of Ni-based superalloys

“…Also, the designed tools are sensitive to the experimental setups used in testing, e.g., machine tools and fixtures. & Finite element method (FEM): it has been employed in simulation of the cutting process, targeting reducing the number of physical experiments [29][30][31], and a well-developed FEM model can therefore provide a reference for cutting tool design [32]. Although FEM has a great potential benefit in terms of cost and efficiency, the cutting process cannot be represented accurately, in which it is hard to guarantee a critical design requirement of cutting tools, especially in machining of superalloys.…”

Tailored Chip Breaker Development for Polycrystalline Diamond Inserts: FEM-Based Design and Validation

“…Although numerous tool manufacturers still base their tool-designs on try-and-see methods based on their previous experience [19], FEM is considered a reliable tool to assess the relative performance of several designs of engineering components, and has been extensively used for the design of cutting tools [32][33][34]. Gurbuz et al [35] pointed out the significance of FEM to evaluate different design geometries to determine a final design before manufacturing, which is substantially cheaper than trial and error methods.…”