Experimental and Finite Element Analysis on Chip Formation Mechanism in Machining of Elastomers

Computer simulation of metal cutting processes using the Finite Element Analysis (FEA) method are routinely practiced in today?s industry. It is known from the theory of metal cutting that an examination of machined chips provides the cheapest and the most effective way of understanding the machining characteristics of a material. This paper discusses experimental work and finite element analysis to investigate the mechanism of chip formation during machining of Elastomer. Focus of this study is on understanding the influence of different cutting parameters on chip formation mechanism. From the experimental tests, it has been concluded that the morphology of rubber chips can be categorized into continuous ribbon-like chips with a smooth machined surface, segmented chips with a rough machined surface, and discontinuous chips with an even worse surface finish. Continuous ribbon-like chips are associated with a smooth surface finish, which occurs with large rake angle tools. Further from Finite Element Analysis it was observed that at lower rake angle, discontinuous chips are formed and Continuous ribbon-like chip occurs with large rake angle.