In: Journal of Machine and Forming Technologies

Volume 3, Issue 1/2

ISSN: 1947-4369
2011 Nova Science Publishers, Inc.

ON THE FUNDAMENTALS OF ORTHOGONAL

METAL CUTTING
P.A.R. Rosa*, V.A.M. Cristino, C.M.A. Silva, P.A.F. Martins
IDMEC, Instituto Superior Tecnico, TULisbon, Av. Rovisco Pais, 1049-001
Lisboa, Portugal

Abstract
This paper is based on the proposition by Atkins (2003) that the physics behind the
separation of material at the tip of the tool is of great importance for understanding the
mechanics of chip formation. Knowledge on how material separates along the parting
line to form the chip and how to include the significant fracture work involved in the
formation of new surfaces, as well as the traditional components of plastic flow and
friction, are presently the most disturbing issues of the fundamental metal cutting
research. This work attempts to provide answers to these issues by means of a combined
numerical and experimental investigation based on the interaction between finite
elements and modern ductile fracture mechanics. The overall presentation is supported by
specially designed orthogonal metal cutting experiments that were performed on lead test
specimens under laboratory-controlled conditions. Comparisons between theoretical
predictions and experimental results comprise a wide range of topics such as material
flow, primary shear plane angle, cutting force and specific cutting pressure. The paper
shows that numerical modelling of metal cutting exclusively based on plasticity and
friction is suitable for estimating material flow, chip formation and the distribution of the
major field variables whereas the contribution of ductile fracture mechanics is essential
for obtaining good estimates of cutting forces and of the specific cutting pressure.

Keywords: Metal cutting, Experimentation, Finite element method, Ductile

fracture.

1.

Introduction

In a recent paper, Astakhov (2005) discussed the major drawbacks of the single shear
plane model for metal cutting, showing that this model cannot be utilized in the
development of the predictive metal cutting theory as well as in the development and
utilization of finite element computer programs. As initially claimed by Cook et al.
(1954) and later by Atkins (2003), the single shear plane model is inadequate for real
metal cutting because it cannot operate in plane strain plasticity at constant plastic
volume without new surface formation at the tip of the tool. In connection to this,
*

Corresponding author: Fax: +351-21-8419058, E-mail: pedro.rosa@ist.utl.pt