Mehrdad Ghatrehnaby - Islamic Azad University, Pardis Branch

Machining and chip formation is a complicated computational problem and is particularly important in the design of new tools and specification of conditions for their use. This study presents a finite element simulation of continuous chip formation in orthogonal machining of an aluminum alloy embedding Johnson cook plastic model in order to analyze the effects of rake angle, edge radius and friction variation on residual stress and plastic strains on the machined surface. A ۳D model using finite element ABAQUS/EXPLICIT general code is created while Jonson Cook damage model is employed to simulate chip separation. The simulations show that generally the residual stress on the surface is slightly smaller than the residual stress right beneath the surface which can be explained by more degrees of freedom on the machined surface. Moreover, as we move away from the surface the residual stress reduces drastically. The simulations also demonstrate that the residual stress increases as the friction coefficient increases and the nose radius gets larger values, while it decreases as the rake angle increases.

Orthogonal machining, residual stress, Rake angle, edge radius, friction, finite element analysis