Finite Element Modelling of Edge Radius Effect in Micro Turning Process

Micro-turning is very similar to conventional turning, but is a cutting operation in which the tool geometry effect is more important. For this reason, the cutting geometry and cutting parameters used in micro turning must be carefully selected. In this work, during the machining of the Ti6Al4V alloy in micro cutting conditions, the effect of different edge radii of the insert on the cutting forces, tool stresses, and residual stresses was investigated. The appropriate material model is determined by comparing the force data obtained from the cutting experiments with the model results. Numerical solutions have been made for different edge radii. The cutting speed and depth of cut were considered as constant. Different feed rate values and different edge radii were chosen as variables. According to the results obtained, the increasing edge radius causes an increase in cutting (especially in the direction of feed) forces. Increasing edge radius causes a decrease in tool stresses. Most importantly, the increase of the edge radius causes the residual stresses under the surface to occur, usually in the form of compression.