Modeling and analysis of scraping forces using finite element method

Scraping is a metalworking method used by many industries to obtain good flatness, low friction, and good lubricating properties on metal surfaces. Scraping requires manual operation, which has the unique kinematic feature of changing the cross-sectional area with tool movement. Scraping is conducted by hand and has the unique kinematic characteristic of changing the cross-sectional area in response to tool movement. As scraping involves micromaterial removal, the chip is partially sheared and plowed around the cutting-edge area, strengthening the size effect. The focus of this study is to develop a scraping force prediction model and to predict scraping forces. The scraping force is first modeled with full consideration of the kinematics, material properties, and size effects. The work of a skilled worker is analyzed to obtain tool geometry and kinematic parameters with SEM and a high-speed camera. A finite element (FE) model of an orthogonal microcut with a round cutting edge is developed accordingly. Through a series of FE simulations, cutting force coefficients are determined for a specific cutting-edge radius and a range of cutting depths. Finally, the established scraping force model is used to predict the scraping force variation in conjunction with actual scraping and the geometric characteristics of the tool. The results of this study provide a basis for real-time monitoring of scraping and optimization of the scraping parameters. The results contribute to a full understanding of manual scraping to promote automatic scraping in the future.