INVESTIGATION OF SIZE-EFFECTS IN MACHINING WITH GEOMETRICALLY DEFINED CUTTING EDGES |
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| Affiliation: |
a Institute for Reliability of Components and Systems (izbs), University of Karlsruhe (TH), Germany
b Institute of Material Science and Engineering I (iwk I), University of Karlsruhe (TH), Germany
c Institute of Production Science, (wbk), University of Karlsruhe (TH), Germany |
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| 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. |
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| Keywords: | Finite element simulation Machining Micro-cutting Size-effect Similarity mechanics Specific cutting force |
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