Details
| Original language | English |
|---|---|
| Article number | 113367 |
| Number of pages | 9 |
| Journal | International Journal of Solids and Structures |
| Volume | 315 |
| Early online date | 5 Apr 2025 |
| Publication status | Published - 1 Jun 2025 |
Abstract
This study examines local friction behavior at the chip–tool interface in metal cutting by integrating chip formation and microscale contact simulations. This research examines the mechanical effects of high-pressure metalworking fluid (MWF) supply on chip formation, specifically its impact on frictional interactions at the tool–chip interface. Through finite element modeling and a microscale contact model, this study provides detailed insights into the effects of high-pressure MWFs on local friction coefficients, contact length, and pressure distribution in the secondary shear zone. Experimental validation using high-speed orthogonal cutting tests demonstrates strong agreement between simulated and observed results, confirming the effectiveness of the multi-scale model. The findings suggest that optimized high-pressure lubrication significantly enhances tool life, reduces process forces, and improves surface quality, making it a valuable strategy for advanced machining applications.
Keywords
- Chip formation simulation, Contact simulation, Fluid–structure interaction, Metalworking fluid, Orthogonal cutting
ASJC Scopus subject areas
- Mathematics(all)
- Modelling and Simulation
- Materials Science(all)
- General Materials Science
- Physics and Astronomy(all)
- Condensed Matter Physics
- Engineering(all)
- Mechanics of Materials
- Engineering(all)
- Mechanical Engineering
- Mathematics(all)
- Applied Mathematics
Cite this
- Standard
- Harvard
- Apa
- Vancouver
- BibTeX
- RIS
In: International Journal of Solids and Structures, Vol. 315, 113367, 01.06.2025.
Research output: Contribution to journal › Article › Research › peer review
}
TY - JOUR
T1 - Investigation of the local friction behavior in the secondary shear zone by coupling of chip formation and microscale contact simulation
AU - Kim, Minjae
AU - Schenzel, Jan
AU - Pape, Florian
AU - Bergmann, Benjamin
AU - Denkena, Berend
AU - Poll, Gerhard
N1 - Publisher Copyright: © 2025 The Authors
PY - 2025/6/1
Y1 - 2025/6/1
N2 - This study examines local friction behavior at the chip–tool interface in metal cutting by integrating chip formation and microscale contact simulations. This research examines the mechanical effects of high-pressure metalworking fluid (MWF) supply on chip formation, specifically its impact on frictional interactions at the tool–chip interface. Through finite element modeling and a microscale contact model, this study provides detailed insights into the effects of high-pressure MWFs on local friction coefficients, contact length, and pressure distribution in the secondary shear zone. Experimental validation using high-speed orthogonal cutting tests demonstrates strong agreement between simulated and observed results, confirming the effectiveness of the multi-scale model. The findings suggest that optimized high-pressure lubrication significantly enhances tool life, reduces process forces, and improves surface quality, making it a valuable strategy for advanced machining applications.
AB - This study examines local friction behavior at the chip–tool interface in metal cutting by integrating chip formation and microscale contact simulations. This research examines the mechanical effects of high-pressure metalworking fluid (MWF) supply on chip formation, specifically its impact on frictional interactions at the tool–chip interface. Through finite element modeling and a microscale contact model, this study provides detailed insights into the effects of high-pressure MWFs on local friction coefficients, contact length, and pressure distribution in the secondary shear zone. Experimental validation using high-speed orthogonal cutting tests demonstrates strong agreement between simulated and observed results, confirming the effectiveness of the multi-scale model. The findings suggest that optimized high-pressure lubrication significantly enhances tool life, reduces process forces, and improves surface quality, making it a valuable strategy for advanced machining applications.
KW - Chip formation simulation
KW - Contact simulation
KW - Fluid–structure interaction
KW - Metalworking fluid
KW - Orthogonal cutting
UR - http://www.scopus.com/inward/record.url?scp=105002145579&partnerID=8YFLogxK
U2 - 10.1016/j.ijsolstr.2025.113367
DO - 10.1016/j.ijsolstr.2025.113367
M3 - Article
AN - SCOPUS:105002145579
VL - 315
JO - International Journal of Solids and Structures
JF - International Journal of Solids and Structures
SN - 0020-7683
M1 - 113367
ER -