Research in Engineering and Aviation

Thermally Assisted High Efficiency Ductile machining of Brittle Materials: a Numerical Study

June 2013

Author(s): J. Ma, N. Pelate, S. Lei

ASME 2013 International Manufacturing Science and Engineering Conference, MSEC2013, June 10-14, 2013, Madison, Wisconsin, USA.


This study investigates the role of thermal assistance and tool geometry on ductile regime machining of a nHAP bioceramic using numerical simulation. FEM is used to conduct the simulation of orthogonal machining of the nHAP. Thermal boundary conditions are specified to approximate laser preheating of the work material. The effects of operating conditions (preheat temperature, rake angle, and edge radius) on pressure distribution, cutting force, and thrust force are investigated. Based on the pressure-based criterion for ductile regime machining, the dependence of critical depth of cut on preheating temperature is examined. It is found that for different combinations of rake angle and edge radius, the critical depth of cut increases as thermal boundary temperature increases. In addition, it is concluded that using higher thermal boundary temperature for smaller negative or zero rake angle, we can achieve the comparable critical depth of cut obtained by using a higher negative rake angle, which usually generates higher thrust force and consequently deteriorates the dimensional accuracy of finished parts