FEM machining analysis: influence of rake angle in cutting of aluminium alloys using Polycrystalline Diamond cutting tools

In this paper, a prediction of the thermo mechanical behaviour of the machining of an aluminium alloy is made, using a Polycrystalline Diamond (PCD) cutting tool with a variable rake angle. To aid the study, a commercial machining finite element software was used and several parameters In conclusion, from the simulations made, it was possible to predict a positive influence of the inclusion of rake angle in PCD cutting tools. A reduction of cutting forces and temperature was shown with the increase of the rake angle, allowing this way an additional extension of the tool life.