Research and modeling workpiece edge formation process during orthogonal cutting

This paper presented the study of the phenomenon of the material deformation at the edge of the workpiece during the orthogonal cutting of steel C45E and two-dimensional model of this process, developed with using the Finite Element Method. Based on the user's procedure VUMAT, the Johnson–Cook's law and Ductile Damage model were applied to describe the machined material. An extensive verification of the modeled process was performed. The phenomenon of material deformation at the edge of the workpiece during the actual orthogonal cutting process was recorded using a high speed camera. The courses of the real phenomenon with the modeled one were compared. The components of the resultant cutting force were measured during orthogonal cutting for different machining parameters. The measurement results were compared with the values of the components of the resultant cutting force calculated on the basis of numerical simulation. The studies on the burr formation mechanism were performed. The contactless measurement of selected geometric features of the burr was performed. The results of measurements of the selected geometric features of burrs obtained from the experiment were compared with those compiled based on FEM simulation.