Numerical modelling of meso-scale finish machining with finite edge radius tools

Finite edge radius plays a significant role in finish machining processes when the undeformed chip thickness is often less than a few hundred microns and comparable to the size of the cutting edge. At suboptimal cutting speeds, edge radius tools may induce deeper subsurface plastic deformation, increase microhardness through work-hardening and mostly due to the ploughing of the cutting edge. Once tool edge radius, tool geometry and cutting conditions are optimised, finish machining can produce superior surface properties than surfaces generated by grinding and polishing. In this paper, an Arbitrary Lagrangian Eulerian (ALE)-based numerical modelling is employed. The Johnson-Cook (J-C) plasticity model is used to describe the work material behaviour. A detailed friction modelling at the tool-chip interface is also carried. Numerical modelling revealed stress and temperature fields induced by the finite edge radius cutting edge on the machined subsurface.