Title: FEM machining analysis: influence of rake angle in cutting of aluminium alloys using Polycrystalline Diamond cutting tools

Authors: C. Maranhao, J. Paulo Davim, M.J. Jackson, G. Cabral, J. Gracio

Addresses: Department of Mechanical Engineering, University of Aveiro, Campus Santiago, 3810-193 Aveiro, Portugal. ' Department of Mechanical Engineering, University of Aveiro, Campus Santiago, 3810-193 Aveiro, Portugal. ' Centre of Advanced Manufacturing, College of Technology, Purdue University, West Lafayette, IN 47907-2021, USA. ' Department of Mechanical Engineering, University of Aveiro, Campus Santiago, 3810-193 Aveiro, Portugal. ' Department of Mechanical Engineering, University of Aveiro, Campus Santiago, 3810-193 Aveiro, Portugal

Abstract: In this paper, a prediction of the thermo mechanical behaviour of the machining of an aluminium alloy is made, using a Polycrystalline Diamond (PCD) cutting tool with a variable rake angle. To aid the study, a commercial machining finite element software was used and several parameters In conclusion, from the simulations made, it was possible to predict a positive influence of the inclusion of rake angle in PCD cutting tools. A reduction of cutting forces and temperature was shown with the increase of the rake angle, allowing this way an additional extension of the tool life.

Keywords: FEM; finite element method; machining; rake angle; PCD; polycrystalline diamond; aluminium alloys; thermomechanical behaviour; cutting forces; temperature; tool life.

DOI: 10.1504/IJMPT.2010.029469

International Journal of Materials and Product Technology, 2010 Vol.37 No.1/2, pp.199 - 213

Published online: 30 Nov 2009 *

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