Simulation of orthogonal cutting: the effect of separation criteria and cutting tool geometry

摘要

A central step in understanding the mechanism of a material cutting process is the investigation of chip formation. Therefore, to build up a reliable finite element model for orthogonal cutting simulation, the chip formation phases must be analyzed first. In this study, the finite element analysis was applied to model and simulate the chip formation and the contact phaenomena during the orthogonal cutting of metals. The material behavior during separation was modelled with a feasible constitutive equation that allows element death to occur upon rupture. The chip separation criteria were based on a critical accumulative effective plastic strain. A comparision with the relevant analytical solution of cutting forces was used to correlate the threshold of separation. Some special techniques were used to treat the contact and the generation of new contact surface during chip separation. The effects of local rake angle on cutting forces and residual stresses were addressed. The cutting forces and surface residual stresses were predicted with respect to cutting tool geometry.