Numerical Modeling of the Effect of Cutting-Edge Radius on Cutting Force and Stress Concentration during Machining

Cutting is the primary method of material removal, and the quality of machined parts depends on the geometry of cutting tools. In this paper, a new cutting force coefficient model is established, revealing the influence of cutting-edge radius on the cutting process. The effects of cutting-edge radius on the shear angle and cutting force components are analyzed by finite element simulations. A series of simulations is conducted, and the results show that with increased cutting-edge radius, the shear angle decreases nonlinearly, and the cutting force increases gradually. Additionally, the growth rate of the feed force caused by increasing the cutting-edge radius is higher than that of the tangential force. Furthermore, the stress concentration area of the machined surface extends from the surface to the subsurface as the cutting-edge radius increases. The results of this research show that changing the cutting edge affects the cutting force component, shear angle, and stress concentration range during the cutting process. These results provide a theoretical reference for predicting the residual stress in parts.

Automated summary

The study establishes a new cutting force coefficient model and investigates the influence of cutting-edge radius on the shear angle, cutting force components, and stress concentration range during the cutting process. The results provide a theoretical reference for predicting residual stress in parts.