Physics-Based Simulations of Chip Flow over Micro-Textured Cutting Tool in Orthogonal Cutting of Alloy Steel

Physics-based process simulations have the potential to allow virtual design and development of digital twins for smart machining applications. This paper presents 3D cutting using finite element method (FEM) investigates physical state variables that are fundamental reduction in forces, friction, tool wear when micro-textured tools employed. For this goal, textured cemented carbide inserts designed, fabricated, tested orthogonal dry a nickel-chromium-molybdenum alloy steel. Cutting forces friction coefficients compared against non-textured tool, revealing effects texture parameters. Chip flow over surface at chip-tool contact investigated compared. The results reveal sources such improvements. Archard’s rate as composition is utilized compare experimental simulated on tools. conditions adhesion characteristics further discussed simulation with comparisons. It was found obtained from these provide insights about