Numerical investigations on tool edge preparation effects on dry cutting of AA2024

This work investigates how honed and chamfered tool edges affect orthogonal machining performance of aerospace aluminium alloy AA2024. A finite element framework, coupling material’ fracture energy and its ductile damage to model chip creation and residual stress development under finishing conditions. Thermo-mechanical simulations were executed to replicate real machining conditions, while chip morphology and cutting force trends were validated against previously reported experimental findings. The analysis highlights how tool edge design affects chip behaviour, force evolution, and subsurface stresses, offering guidance for selecting edge geometries in dry machining of AA2024.