The development and implementation of a plane-strain finite element method for the simulation of orthogonal metal cutting with continuous chip formation are presented. Detailed work-material modeling, including the effects of elasticity, viscoplasticity, temperature, large strain, and high strain-rate, is used to simulate the material deformation during the cutting process. The unbalanced force reduction method and sticking-sliding friction behavior are implemented to analyze the cutting process. The deformation of the finite element mesh and comparisons of residual stress distributions with X-ray diffraction measurements are presented. Simulation results along the primary and secondary deformation zones and under the cut surface, e.g., the normal and shear stresses, temperature, strain-rate, etc., are presented revealing insight into the metal cutting process.

Issue Section:
Technical Papers
Topics:
Finite element analysis, Metal cutting, Simulation, Deformation, Cutting, Temperature, Elasticity, Finite element methods, Friction, Modeling, Plane strain, Shear stress, Simulation results, Stress, Viscoplasticity, X-ray diffraction
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