Stress Distribution in Orthogonal Machining: A Finite Element Analysis

High speed machining is governed by the tool material an its geometry. It has hence been ever interesting to realise the exact behaviour of the tool under the process. A general view on machining, tool and involved forces and their available analyses is presented. FE analysis of stress distribution on the rake face, as a crucial factor on tool life, has been limited to constitutive flow stress models and friction conditions applicable whithin the FE packages. A comprehensive FE analysis based on five different flow stress models and variable friction conditions is presented using Deform 2D package on AISI1045 steel. High deformation criterion for metal forming, modified constitutive flow stress models and complicated friction conditions were applied in the package without numerical instabilities which makes the work distinctive. Predictions were in good agreement to the experimental studies and suggest a reliable benchmark of the package capabilities to understand the stress distribution mechanism in orthogonal cutting.