A study of the tool-chip interface contact problem under low cutting velocity with an elastic cutting tool

To understand the effects of elastic deformation of the tool and the crater phenomenon generated by the cutting force and high pressure during metal cutting processing on the cutting process, an iterative mathematical model for calculating the tool-chip contact is developed in this paper under the assumption of elastic cutting tools. In this model, the finite-element method is used to simulate the cutting of mild steel by a cutting tool of three different materials. The results obtained in the simulation are found to match experimental data reported by related studies. The simulation results also indicate that tools with a smaller stiffness produce greater elastic deformation. Further, decrease of the rake angle due to elastic deformation of the tool can result in greater difficulty in internal deformation of the material and an increase in cutting force. The micro-crater phenomenon on the tool face generated by high pressure at the tool-chip interface is the preliminary symptom of crater wear on the tool face. Therefore, under some machining conditions, such as in precision machining or in automation processing where tool compensation is required, the phenomenon of elastic deformation of the tool must be considered carefully to ensure product precision.