Analysis of the Effect of Cutting Parameters on Cutting Force and Temperature in Thermo-Mechanical Coupled Orthogonal Cutting of Polyethylene (PE)

PE material is an ideal type of material for improving corrosion and impact resistance of engineering structural applications, because of its excellent corrosion resistance, low coefficient of friction, and favorable impact resistance. PE structural components generally require precise machining forming in order to satisfy diverse structural and functional requirements. However, PE materials exhibit pronounced temperature sensitivity and thermal softening during the cutting process. The cutting heat generated by plastic deformation and interfacial friction within the cutting zone can significantly influence the local mechanical properties of the material, the cutting-force response, and the resulting surface integrity. This study investigated the cutting mechanism of polyethylene materials through numerical simulation. Based on the mechanical characteristics of PE, a progressive damage constitutive model of the material was defined. Furthermore, a three-dimensional thermo-mechanically coupled cutting model was developed. The accuracy of the proposed model was verified through comparison with previous experimental data. The orthogonal cutting process of polyethylene (PE) was numerically simulated, and the effects of cutting speed and cutting depth on the stress and strain distributions, cutting temperature, and chip formation behavior were systematically analyzed. The influence of key machining parameters on the cutting performance of PE was further evaluated, and the thermomechanical coupling behavior during the cutting process was investigated. The present study not only deepens the understanding of the cutting mechanism of PE materials, but also provides a theoretical basis for the optimization of polyethylene machining processes and cutting tool design.