Investigation of the local friction behavior in the secondary shear zone by coupling of chip formation and microscale contact simulation

verfasst von

Minjae Kim, Jan Schenzel, Florian Pape, Benjamin Bergmann, Berend Denkena, Gerhard Poll

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.

Organisationseinheit(en)

Institut für Maschinenkonstruktion und Tribologie
Institut für Fertigungstechnik und Werkzeugmaschinen

Typ

Artikel

Journal

International Journal of Solids and Structures

Band

315

Anzahl der Seiten

9

ISSN

0020-7683

Publikationsdatum

01.06.2025

Publikationsstatus

Veröffentlicht

Peer-reviewed

Ja

ASJC Scopus Sachgebiete

Modellierung und Simulation, Allgemeine Materialwissenschaften, Physik der kondensierten Materie, Werkstoffmechanik, Maschinenbau, Angewandte Mathematik

Elektronische Version(en)

https://doi.org/10.1016/j.ijsolstr.2025.113367 (Zugang: Offen)