The influence of tool micro-geometry on stress distribution in turning operations of AISI 4140 by FE analysis

Summary, in English

Abstract This paper aims to gain a better understanding of the impact different micro-geometries has on stress distribution in cutting tools. Both principal and effective stress distribution are studied since these quantities have a major impact on the occurrence of damages in the cutting tool such as crack formation, flaking, chipping, breakage and plastic deformation. The development of a stagnation zone has also been investigated and the effect tool micro-geometries have on this zone. A finite element model has been developed which enables the examination of these aspects, in detail. The model was able to predict these metal cutting phenomena with high accuracy. Cutting forces is within the standard deviation of experimental results, stress distributions and the stagnation zone is also simulated correctly indicated by experimental results. This study has shown that the micro-geometries of the cutting tool have a great potential in order to reduce the maximal tensile/principal stress. This research work also shows that the size of the stagnation zone can be controlled by micro-geometries on the cutting tool, which can have an effect on the wear on the cutting edge.