Numerical simulation and analytical modelling of ploughing and elastic phenomena during machining processes

The present work deals with the presentation of an analytical methodology allowing the modelling of chip formation. For that, a 'phenomena split method', based on assuming that the material removal is the contribution of three phenomena, ploughing, spring back and 'pure cut', is developed. In particular, the elaboration of analytical sub-model of ploughing and spring back is presented in detail. FEM simulations and experimental data concerning temperatures and forces evolution are exploited to calibrate and verify the proposed analytical model dealing with 'ploughing and spring back'. It is possible with this model to understand the physics of chip formation, and model lateral burrs and elastic phenomena under the tool and at the rear (spring back). The cutting radius contribution is analysed, which is important to the understanding of the tool wear and the residual stresses in the finished work-piece.