Finite Element Simulation Of Friction On Tool-Chip Interface In Metal Cutting Process

It is still very important and difficult to understand the tool-chip interface friction in metal cutting process. Because of high temperature and high stress in the interaction between chip and tool rake face, experiment data is hard to measure, the contact process is hardly possible to observe, and theory analysis is difficult. The research development on the tool-chip interface friction is very slow. In recent years, finite element methods have been widely used in research and industrial applications because of the advancements in computational efficiency and speed. In particular, FEM is a useful tool for the analysis of metal cutting processes. Because it is not only imaginable and direct, but also can incorporate strain, strain rate and temperature effects, as well as complicated friction behavior.Based on the research of the tool-chip interface friction theories, the finite element models of metal cutting are established using Deform-2D software. And the important technology of the mesh generation, the friction model, chip separation criteria and the producing and conduction of the cutting heat are investigated. A revised sticking-sliding friction model on the tool-chip interface using numerical simulation technology through comparing with experimental data is presented. And the cutting processes are predicted at different cutting parameters.By finite element simulation, the distributions of stress, temperature and strain on the tool-chip interface at different cutting parameters are obtained, the effects of cutting speeds and depths on contact state parameters are analyzed; the distributions of friction shear stress and temperature are received through simulations, the effects of contact state parameters on the sticking-sliding separated points are discussed comprehensively; the sticking-sliding separated points at a series of cutting parameters are obtained, the relationship between the contact friction state and cutting parameters is analyzed; and the three dimensional finite element model is established, tool wear at different cutting parameters is predicted and analyzed.