Further Development of a Finite Element Model of Orthogonal Metal Cutting: Final Report

摘要

This report summarizes the improvement of two finite element models of orthogonal metal cutting. The research effort took place from January 1985 to September 1987. Two contracts were awarded during this period, each aimed at specific improvements to the two models. The first contract consisted of four tasks, which concentrated on the further development of a NIKE2D metal cutting model. These included the following: the criterion for separation of finite element nodes into chip and workpiece near the tool tip; the most appropriate treatment of the stress concentration near the tool tip; the addition of thermal effects to the calculations, including heating from plastic work and interfacial friction, thermoelastic-plastic material properties, internal heat conduction and free-surface heat removal; and in collaboration with the Lawrence Livermore National Laboratory (LLNL), North Carolina State University (NCSU) shall conduct parameter studies, based on the existing state of code development, for factors such as tool edge radius, rake angle, etc., aimed at comparisons with experiment and guidance of code development. The second contract called for improvements to a second type of finte element model of orthogonal metal cutting. This model is called the Eulerian model because it simulates the workpiece in the vicinity of the cutting tool as an Eulerian flow field. The tasks under this contract included the following: development of a free surface algorithm for chip geometry for the cutting model; preliminary development of a transient Eulerian cutting model; and assessment of the use of an Eulerian model to study the onset of shear band formation and built-up edge as a function of cutting conditions, such as cutting speed, depth of cut, rake angle, and material properties. (ERA citation 13:015686)