FINITE-ELEMENT ANALYSIS OF ORTHOGONAL METAL-CUTTING MECHANICS

The plane-strain finite element method is developed and applied to ana lyze the orthogonal metal cutting with continuous chip formation. Deta iled work-material modeling, which includes the coupling of large stra in, high strain-rate and temperature effects, is implemented. The vers atility of the finite element method is demonstrated by presenting sim ulation results to complement the experimental measurements and to gai n better understanding of the mechanics of the tool-chip contact and w ork-material deformation. The contour plots are used to show the distr ibution of parameters in the deformation zones. The finite difference method is applied to estimate the rate of change of parameters with re spect to time. The Eulerian description of the deformation of work-mat erial is also presented to show the variation at seven selected elemen ts, which are expected to pass the deformation zones or go underneath the worn cutting tool.