文献类型：期刊文献

英文题名：A predictive model of micro-cutting forces and thermal behavior in 7075 aluminum alloy considering maximum feed per revolution

作者：Zhang, Ping[1,2]; Wang, zhencui[1]; Zhang, Songting[1]; Jiang, Xiaomin[1]; Yue, Xiujie[2,3]

机构：[1] College of Mechanical and Power Engineering, Guangdong Ocean University, Zhanjiang, China; [2] College of Intelligent Manufacturing, Qingdao Huanghai University, Qingdao, 266520, China; [3] College of Intelligent Manufacturing, Qingdao University of Technology, Qingdao, 266520, China

年份：2026

卷号：48

期号：1

外文期刊名：Journal of the Brazilian Society of Mechanical Sciences and Engineering

收录：EI(收录号：20254819607611)、Scopus(收录号：2-s2.0-105023095808)

语种：英文

外文关键词：ABAQUS - Cutting - Cutting tools - Micromachining - Thermoanalysis

外文摘要：This study conducts an in-depth analysis of the micro-cutting mechanisms and cutting force characteristics of 7075 aluminum alloy, emphasizing the influence of tool edge radius, cutting depth, and feed rate. A novel theoretical model is developed that captures the asymmetric force distribution induced by the tool’s finite edge radius, particularly in the region above the chip separation point. In contrast to conventional empirical approaches, the proposed model introduces a geometry-based criterion for determining the maximum permissible feed per revolution, thereby addressing critical limitations in traditional microscale cutting models. To assess the accuracy of the theoretical predictions, a two-dimensional orthogonal cutting simulation is performed using the ABAQUS finite element platform. The simulated cutting forces, including both the primary and radial components, exhibit strong correlation with the theoretical predictions, with maximum relative deviations limited to 14.1% and 17.8%, respectively. These discrepancies remain within acceptable engineering margins, confirming the model’s predictive reliability. The robustness and practical applicability of the model are further validated through a series of controlled single-factor cutting experiments. Experimental results demonstrate that cutting depth is the most significant factor influencing the main cutting force, whereas the tool edge radius predominantly affects the radial cutting force. Additionally, a comprehensive thermal analysis reveals that cutting depth markedly elevates the tool’s peak temperature, while edge radius slightly enlarges the thermal diffusion zone. In contrast, feed rate exhibits relatively minor influence on both thermal and mechanical responses within the examined parameter range. Importantly, the experimentally observed trends closely align with the simulation outcomes, substantiating the physical relevance and reliability of the proposed model. These results confirm that the model not only reflects the fundamental cutting behavior but also holds practical significance for optimizing micro-machining processes. By integrating geometric constraints with a thermomechanical coupling framework, this work offers a unified and physically grounded methodology for predicting cutting forces under realistic micro-cutting conditions. The findings provide valuable insights for the development of precision manufacturing strategies, particularly in applications demanding high accuracy and material integrity at the microscale. ? The Author(s), under exclusive licence to The Brazilian Society of Mechanical Sciences and Engineering 2025.