The Cutting Interference Research During Circular Tool Cutting By FEM

During cutting process, the chip needs to coordinate to form an integral part. However, this process would lead to cutting interference. Cutting interference is very common in cutting process, and would bring about some negative influences, for example, the increase of cutting force, energy-consumption, wearing of tools and cutting temperature. Therefore, having an in-depth knowledge about the theory of cutting interference is meaningful and the problems mentioned above would be completely solved. Whereas, there were only few articles that studied the cutting interference, partly because researchers needed to do plenty of experiments to find certain ways to reduce the influence of the cutting interference, in which process a lot of materials were used and the experiments would cost plenty of time. For so many reasons, based on the FEM software, this article studied the cutting interference, analysed the influence of chip splitting and rake angle on the cutting interference. The main contents are as below:At first,the accuracy of the two kinds of FEM software was compared, and the better one was chosen to study the influence of the cutting interference. The characteristics of ABAQUS were analysed, and the model to study the cutting interference was established.Furthermore, three different kinds of workpiece were compared, and the best one was chosen to do the experiment. Through orthogonal machining of copper, the various values of chip-tool friction were gotten, and a formula to estimate the chip-tool friction about cutting copper was put forward. Various values of the chip-tool friction were gotten through this formula. According to the experimental data about orthogonal machining of 45 steel, a formula to estimate chip-tool friction about cutting 45 steel was put forward. Various values of chip-tool friction were gotten.At last, the influence of mesh on the accuracy of FEM was analysed, and the best mesh density was chose to analyse the influences of chip splitting and rake angle on the cutting interference, and the influences of different values of chip-tool friction on the cutting interference were compared.According to the above analysis, the values of chip-tool friction have a great influence on the accuracy of FEM. It is necessary to get the values of chip-tool friction before FEM. The mesh density is also of great influence on FEM, it is necessary to get the best mesh density through experiments before FEM. Chip splitting and rake angle can reduce the cutting interference, but it is very important to choose the number of chip splitting and the degree of rake angle.