Simulation and experimental verification of the effects of rake angle on cutting forces and mechanical stresses

In this study, experimental measurement of cutting forces (turning) during chip removal turning process and simulation of cutting in the same condition via DEFORM 3D software were aimed. The cutting forces obtained by experiment were compared to simulation results, then mechanical stresses and their effects on cutting tools were determined. At the experiments, various cutting parameters and cutting tools having different chip breaker forms were used on the materials of AISI 1050, AA 2011 and AA 7075. The cutting forces were measured by a 9257B Kistler dynamometer. The effects of rake angle, chip breaker form, cutting velocity, feed rate, and cutting tool geometries on cutting tool stresses were investigated. The main cutting forces obtained experimentally and DEFORM 3D simulation shown very close distribution and the values obtained could be used in practice. At the consequences of analyses, it was observed that cutting tool geometry, chip breaker form, nose radius, and cutting parameters provide reliable information with respect to cutting tool stresses, location of stress, and stress distribution. Because of the experimental study to determine cutting forces and mechanical stresses during chip removal is complex, time consuming, and costly and requiring specific tools, Deform 3D software can be used for the prediction/determination of cutting forces and mechanical stresses and to overcome these difficulties.Key Words : Rake angle, cutting forces, cutting tool stresses, DEFORM 3D