Degree Type


Date of Award


Degree Name

Master of Science


Mechanical Engineering


Machining simulations of orthogonal cutting are performed using the finite element method to predict chip formation in grooved tool cutting. A flat-faced cutting tool is first simulated to check the validity of the model, and the results obtained are used as a basis for comparison in grooved tool cutting simulation. Grooved tool simulations are modeled next to investigate the effect of a groove on the chip formation process. Groove depth and width were the two parameters changed for the purpose of analyzing the chip flow characteristics, stress and strain distributions found in the chip.;For all simulated cases, it is observed that a groove definitely impart more curl on the chip, and more tensile and/or compressive near the chip root, a condition conducive to chip breaking. More curling is observed when the groove radius of curvature is reduced by increasing the groove depth or decreasing the groove width. It is also observed that the increase in normal tensile stress at the chip root next to the tool tip is proportional to the amount of curl displayed in the chip. However, the increase in normal compressive stress is related to the increase in chip thickness, a variable that depends on the effective rake angle of cutting.



Digital Repository @ Iowa State University,

Copyright Owner

Wooi Khiong Thean



File Format


File Size

47 pages