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<p>During machining, a near-stagnant material zone, termed the dead metal zone (DMZ), forms in front of the edge-radiused tool, affecting the ploughing forces and overall process performance. Despite its significance, the material behavior within the DMZ and the flow separation remains inadequately understood. This study employs a 2D plain strain analysis using the arbitrary Lagrangian–Eulerian (ALE) method to investigate DMZ formation during orthogonal cutting of aluminum alloys under ploughing-dominated conditions, where the relative tool sharpness (RTS) is less than unity. The influence of uncut chip thickness, cutting velocity, and coefficient of friction (COF) on DMZ formation is analyzed. Results reveal a distinct stagnation region within the DMZ near the tool edge radius, characterized by a stagnation angle of approximately 46°. The COF significantly impacts DMZ size and stagnation region characteristics compared to uncut chip thickness and cutting velocity. Reducing the COF from 0.45 to 0.1 decreases DMZ size from 154.33 μm<sup>2</sup> to 50.26 μm<sup>2</sup> and reduces the stagnation region to a single point. Material separation occurs at the stagnation point, as evidenced by changes in contact shear stress direction. In contrast, no DMZ or subsurface gradients are observed with a sharp tool, highlighting the critical role of the edge radius in machining.</p>

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Numerical investigation on dead metal zone formation in ploughing dominant orthogonal cutting

  • 期刊论文

  • 发表日期：

    2025年9月9日

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  • Suresh Ellappan,
  • Afzaal Ahmed

摘要

During machining, a near-stagnant material zone, termed the dead metal zone (DMZ), forms in front of the edge-radiused tool, affecting the ploughing forces and overall process performance. Despite its significance, the material behavior within the DMZ and the flow separation remains inadequately understood. This study employs a 2D plain strain analysis using the arbitrary Lagrangian–Eulerian (ALE) method to investigate DMZ formation during orthogonal cutting of aluminum alloys under ploughing-dominated conditions, where the relative tool sharpness (RTS) is less than unity. The influence of uncut chip thickness, cutting velocity, and coefficient of friction (COF) on DMZ formation is analyzed. Results reveal a distinct stagnation region within the DMZ near the tool edge radius, characterized by a stagnation angle of approximately 46°. The COF significantly impacts DMZ size and stagnation region characteristics compared to uncut chip thickness and cutting velocity. Reducing the COF from 0.45 to 0.1 decreases DMZ size from 154.33 μm2 to 50.26 μm2 and reduces the stagnation region to a single point. Material separation occurs at the stagnation point, as evidenced by changes in contact shear stress direction. In contrast, no DMZ or subsurface gradients are observed with a sharp tool, highlighting the critical role of the edge radius in machining.