Finite Element Analysis of the Rake Angle Effects on Residual Stresses in a Machined Layer

Abstract

In this paper, a plane strain Finite Element Method is developed and applied to model andsimulate the orthogonal metal cutting of (AISI 1045 St) with continuous chip formation.Seven sets of simulation results for cutting with rake angles (-15o, -10o, -5o, 0o, 5o, 10 o and15o), are summarized and compared to analyze their effects in the cutting process in steadystate condition. Simulation results of the residual stresses below the machined layer arepresented and compared with other papers in the literature and showed good agreement.Simulation results offer an insight into residual stresses through different values of rakeangles. Based on simulation results, characteristics of residual stress distribution can becontrolled by optimizing the rake angle. The simulated results show that for positive rakeangles and position, the zero of maximum effective stress is found to be at (0.04) mmbeneath the work piece surface, while for negative rake angles, the position of maximumeffective stress is changed to be directly on the workpiece surface.