ABSTRACT
This chapter deals with quantitative analysis of the chip formation and material flow that affect the integrity of the tool edge and the machined surface of the workpiece. When dry machining aluminum alloys, the formation of built-up edge (BUE) often occurs at the tool tip, then affecting the chip formation process and the quality of the machined surface. To analyze the effect of the BUE on the chip formation process and tool wear, Lagrangian and Arbitrary Lagrangian Eulerian models were performed by using a local friction coefficient and the real thermomechanical loading along the tool rake face and the round cutting edge at the tool–chip interface. Material characteristics such as strain rate sensitivity, strain hardening, and thermal softening were considered. As an important result of this study, it was noted that the transition from a sliding contact to a sticking–sliding contact changes the chip morphology and thermomechanical fields as the work material velocity, plastic strain, and cutting forces.
