An explicit plane strain FE model using ABAQUS/Explicit was developed to analyze rubber cutting using high-speed steel (HSS) tools. The initial and deformed meshes, as the cutting reaches steady state condition, are first described. The Neo-Hookean constitutive model for the hyperelastic material considering the effective stress failure criterion is then introduced. The advantages of applying explicit method on the simulation of rubber cutting process over its implicit counterpart are discussed. The model was used to predict cutting forces, chip shape, stress and strain fields, and strain energy distribution in the chip and workpiece. Orthogonal cutting experiments were conducted for several rake angles and feeds to validate the FE model. Good agreement was found between the predicted and measured cutting forces. Favorable cutting conditions for formation of a smooth machined surface were identified by both simulations and experiments. The finite element model provides new insight into the chip formation process of rubber cutting.
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