| Tool edge roundness plays a significant role in machining processes. The effect of tool edge roundness was considered in finite element modeling of chip formation in orthogonal metal cutting. Deformation and thermal analysis was carried out for steady-state simulations. Thermal properties were considered to be dependent on temperatures.; A FORTRAN computer program was developed based on the proposed finite element model. The cutting forces and the distributions of stresses, strain-rates, and temperatures were analyzed, and the effects of undeformed chip thickness and cutting speeds were investigated.; The results of the proposed finite element model were compared with those from commercial machining simulation software and validated by the experimental data. |
