Investigation of the local friction behavior in the secondary shear zone by coupling of chip formation and microscale contact simulation
Year: 2025
Type: article
Abstract: This study examines local friction behavior at the chip–tool interface in metal cutting by integrating chip formation and microscale contact simulations. This research examines the mechanical effects of high-pressure metalworking fluid (MWF) supply on chip formation, specifically its impact on frictional interactions at the tool–chip interface. Through finite element modeling and a microscale contact model, this study provides detailed insights into the effects of high-pressure MWFs on local friction coefficients, contact length, and pressure distribution in the secondary shear zone. Experimental validation using high-speed orthogonal cutting tests demonstrates strong agreement between simulated and observed results, confirming the effectiveness of the multi-scale model. The findings suggest that optimized high-pressure lubrication significantly enhances tool life, reduces process forces, and improves surface quality, making it a valuable strategy for advanced machining applications. • Developed a multi-scale simulation coupling chip formation with microscale contact. • Studied high-pressure cooling lubricants’ impact on secondary shear zone friction. • Demonstrated significant friction reduction and tool–chip contact length decrease. • Validated simulation results with high-speed cutting experiments. • Proposed future enhancements integrating thermal effects and coolant formulations.
Institution: Leibniz University Hannover
Language: English
Subfield: Mechanical Engineering
Field: Engineering
Domain: Physical Sciences
Open Access status: hybrid
Estimated APC paid: $3,790
Funder: Deutsche Forschungsgemeinschaft
OpenAlex ID: W4409207827