Analytical modeling to predict the cutting behavior of ferromagnetic steels: A coupled magnetic–mechanical approach

This paper discusses the reliability of a novel constitutive approach to model the magnetically assisted dry cutting of steel. The magnetic force combined with the mechanical force components, was found to be responsible for the perturbation observed in the primary shear angle. This perturbation is considered the basis of the analytical development. Quick-Stop Trials (QST) were first performed on AISI-1045 steel to investigate the shear angle evolution during the chip formation process. Both the Merchant and the Lee–Shaffer models were used to develop the coupled magnetic–mechanical approach. Magnetically free and magnetically assisted orthogonal cutting tests were then conducted to validate the analytical predictions. The shear angle showed a sensitive increase with the magnetic intensity until the steel magnetic saturation limit was reached. A magnetic field seems to be capable of altering the plastic shear, resulting in modification of the chip formation mechanisms. The neat drop observed in contact length proves the ability of the magnetic field to enhance the material flow along the secondary shear zone. The changes at the tool–steel interface, i.e., friction, are found to correlate strongly with the force magnitude change due to the magnetic component. The good agreement between the measurements and predictions demonstrates the efficiency of the proposed approach.