NDLI: Finite element optimization of diamond tool geometry and cutting-process parameters based on surface residual stresses

Content Provider	Springer Nature Link
Author	Zong, W. J. Li, D. Cheng, K. Sun, T. Liang, Y. C.
Copyright Year	2006
Abstract	In this paper, a coupled thermo-mechanical plane-strain large-deformation orthogonal cutting FE model is proposed on the basis of updated Lagrangian formulation to simulate diamond turning. In order to consider the effects of a diamond cutting tool’s edge radius, rezoning technology is integrated into this FE based model. The flow stress of the workpiece is modeled as a function of strain, strain rate, and temperature, so as to reflect its dynamic changes in physical properties. In this way, the influences of cutting-edge radius, rake angle, clearance angle, depth of cut, and cutting velocity on the residual stresses of machined surface are analyzed by FE simulation. The simulated results indicate that a rake angle of about 10° and a clearance angle of 6° are the optimal geometry for a diamond tool to machine ductile materials. Also, the smaller the cutting edge radius is, the less the residual stresses become. However, a great value can be selected for cutting velocity. For depth of cut, the ‘size effect’ will be dependent upon it. Residual stresses will be reduced with the decrement of depth of cut, but when the depth of cut is smaller than the critical depth of cut (i.e., about 0.5 μm according to this work) residual stresses will decrease accordingly.
Starting Page	666
Ending Page	674
Page Count	9
File Format	PDF
ISSN	02683768
Journal	The International Journal of Advanced Manufacturing Technology
Volume Number	32
Issue Number	7-8
e-ISSN	14333015
Language	English
Publisher	Springer-Verlag
Publisher Date	2006-11-02
Publisher Place	London
Access Restriction	One Nation One Subscription (ONOS)
Subject Keyword	FE simulation Diamond turning Residual stresses Optimization Cutting-edge radius Computer-Aided Engineering (CAD, CAE) and Design Mechanical Engineering Production/Logistics Industrial and Production Engineering
Content Type	Text
Resource Type	Article
Subject	Industrial and Manufacturing Engineering Control and Systems Engineering Mechanical Engineering Computer Science Applications Software

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