Numerical & experimental metal cutting analysis: An appraisal

Abstract

Numerical analysis of metal cutting operations is increasingly relied upon in computer experiments, in order to clarify mechanical, thermal and tribological aspects in view of process optimization. The acid question is, however, whether impressive color displays and detailed figures describe what is actually taking place, or if some results might more properly belong to virtual reality. A classic experimental design for second order response surface work, concerning a simple cutting operation on mild steel, was run both in the metal cutting laboratory and on dedicated software, and results compared also in the light of classic models. Agreement concerning responses such as forces, temperature, and cutting ratio, was found to range from definitely fair to quite poor, underlining that reliance on numerical model may not always be fully justified. Analysis of deviations throws some light on a complex situation.