Development of a Friction Model for Cutting Simulations of Lead-Free CuZn-Alloys

The element lead is used as an alloying element in CuZn-alloys with mass contents of up to m<inf>PB</inf>= 4 % to improve machinability properties. Due to its toxicity, a variety of legislative initiatives aim to reduce the lead content in CuZn-alloys, which leads to critical machinability problems and a reduction in productivity of machining processes. In order to improve the machinability of lead-free CuZn alloys, it is imperative to analyze the influencing variables and mechanisms of chip formation in detail. In addition to the experimental analysis of the machining process, numerical modeling approaches can be used for this purpose. So far, no valid chip formation model for the description of the chip formation of lead-free CuZn-alloys has been established. Within the scope of this work, the foundation for the chip formation model is to be laid by developing a friction model for the meshing conditions in the machining process between lead-free brass and carbide. In addition to the material model, this model is the subsequent input variable for the chip formation model and thus enables the numerical simulation of machining processes with lead-free CuZn-alloys.