Mathematical model of plowing forces to account for flank wear using FME modeling for orthogonal cutting scheme

This article develops a model simulating the formation of the tension condition on the flank surface of a tool’s tooth in orthogonal cutting based on the example of face milling and using the plastic theory of contact interaction of bodies. A calculation was performed in the ANSYS/LS-DYNA program using the finite element method. The model allows us to determine the stress value on the cutting tool’s flank surface for various cutting modes. Analysis of the orthogonal cutting process has been carried out using the simulation model that allows the following to be defined: the flank surface stress diagram model, introducing the flank wear value defined by the processes of the shear zone, and contact interaction of the cutting tool’s flank surface and the workpiece. The basic and normal cutting force components in the cross section perpendicular to the cutting edge were obtained. Our main result is the mathematical model of the force in the orthogonal cutting scheme, introducing the force components on the front surface conditioned by the processes of the shear zone and on the flank surface of the cutting tool, introducing the flank wear value.