Finite element analysis for the influence of rake angles of diamond tool on ultraprecision cutting process

Based on large deformation theory and updated Lagrangian procedure, a coupled thermo-mechanical plane strain model of orthogonal cutting process is developed. And resorting to a finite element model, the ultra-precision cutting process of 6061 aluminum alloys is simulated by utilizing general commercial software. The influences of rake angles on cutting forces, chip deformation, maximal strains of chip root and maximal compressive stress on rake face are obtained. Results show that when the rake angle changes from the negative to the positive, chip thickness decreases and chip length increases, curvature radius of chip, cutting forces and maximal compressive stress at the interface between tool and chip decrease, and the cutting temperature near tool tip raises at the same time. However, the maximal strain near chip root keeps a constant. The rank angle of diamond tool should be selected reasonably according to the analysis.