Physics-based simulations of chip flow over micro-textured cutting tool in orthogonal cutting of alloy steel

Physics-based process simulations have the potential to allow virtual process design and the development of digital twins for smart machining applications. This paper presents 3D cutting simulations using the finite element method (FEM) and investigates the physical state variables that are fundamental to the reduction in cutting forces, friction, and tool wear when micro-textured cutting tools are employed. For this goal, textured cemented carbide cutting tool inserts are designed, fabricated, and tested in the orthogonal dry cutting of a nickel-chromium-molybdenum alloy steel. Cutting forces and friction coefficients are compared against the non-textured tool, revealing the effects of texture parameters. Chip flow over the textured tool surface and process variables at the chip-tool contact are investigated and compared. The results reveal the fundamental sources of such improvements. Archard’s wear rate as a composition of process variables is utilized to compare experimental and simulated wear on the textured cutting tools. The effects of texture and cutting conditions on tool wear and adhesion characteristics are further discussed on the simulation results with experimental comparisons. It was found that the results obtained from these simulations provide further fundamental insights about the micro-textured cutting tools.