Numerical simulation investigations into the effect of machining parameters on the cutting process for ZrO2 ceramics

The three-dimensional cutting process of ZrO₂ ceramics was simulated using the finite element simulation method. By studying the chip removal mechanism, dynamic changes and distribution of stress, and changes in cutting force of workpiece materials, it was found that with the increase of machining depth, the stress on the workpiece gradually increases, and the stress layer on the tool surface also gradually expands and increases towards the front and back cutting surfaces. In addition, the cutting force will gradually increase. The stress and cutting force fluctuate with the increase of cutting speed, but there is no obvious change on the whole. The radius of edge circle will affect the formation of crack at the initial stage of cutting, With the increase of the radius of the cutting edge, the crack length at the front of the cutting tool will become shorter, but the effect of cutting force is not obvious. When cutting with negative rake angle of cutting tool, it will not cause cracks in the ceramics and obtain better machining quality. The maximum cutting force increases rapidly when the tool rake angle is 0°. With the increase of tool rake angle, the change of cutting force is not obvious.