Investigating the machining of tungsten (W) using finite element analysis

Tungsten is extensively used as a plasma facing material in fusion energy reactors. A finite element model was created to simulate the machining of tungsten for the first time by estimating the cutting forces and observing the impact of the variation in tool rake angle. The model was validated through machining experiments involving a specially designed single flute fly cutter which indicated errors of 6% – 34%, depending on the rake angle. This investigation is the first step in understanding the impact of cutting parameters on machining of tungsten. However, the model is affected by the unpredictable impact of tungsten’s deformation behaviour and especially the effects of its brittle nature and low fracture toughness.