An integrated approach to the modeling of size-effects in machining with geometrically defined cutting edges

In order to comprehensively investigate size-effects occurring in the miniaturization of cutting prozesses, material science, simulation and experimental testing are combined. Similarity mechanics are used to guide the parameter variation in two-dimensional finite-element simulations for orthogonal cutting using ABAQUS /Explicit. The rate-dependent material model used, leads to size-effects like an increase of the specific cutting force while reducing the depth of cut. The influence of rounded cutting-edges on the chipping process and the characteristics of the generated surface were investigated in 2D-simualtions. Rounded cutting tools are shown to produce severe plastic deformations of the generated surface and deep plastically deformed surface layers.