Study on the Effect of Tool Inclination Angle in Machining Process Based on Three-Dimensional Thermo-Elastic-Plastic Model

Based on large deformation theory and virtual work principle, a coupled three-dimensional (3D) thermo-elastic-plastic finite element model (FEM) was constructed to simulate the high speed cutting process of Al7050-T7451. The mechanical properties of workpiece material under conditions of high temperature and high strain rate were defined in the model. A shear friction model was involved at the interfaces of tool-chip, tool-workpiece. Based on the model, different 3D machining FEM with different inclination angles were established, and distributions of stress, strain and temperature were achieved. Further more, the effects of inclination angle on the chip curling direction, chip flow angle, cutting force and cutting temperature were studied.