This paper studies the performance of restricted cutting tool in dry orthogonal machining of mild steel (AISI 1045 steel) using finite element simulations. The rake face of cemented carbide (WC/Co) cutting inserts is designed and the rake face length is shortened. The purpose is to examine the effect of shortened tools on machining performance and to compare it with regular cutting tools. The following restricted tool parameters are examined: length of rake face, alpha angle (the angle between the rake face and the supporting face), and edge radius. Their effects are assessed in terms of the main force, thrust force, and chip-tool contact length. It is found that restricted cutting tools generate lower cutting force and thrust force and consequently lower the energy necessary for machining. The length of rake face, the angle between the rake face and the supporting face, and edge radius all have influence on cutting force in their own ways. The effects of these three parameters on the tool temperature distribution are also investigated.

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