APPLICATION OF 2D FEM TO CHIP FORMATION IN ORTHOGONAL CUTTING

This paper summarizes the results of an investigation where the FE cod e DEFORM 2D was applied to simulate a plane strain cutting process. To perform the simulation with reasonable accuracy and to study continuo us and segmented chip formation it was necessary to modify the existin g version of the code. Damage criteria have been used for predicting w hen the material starts to separate at the initiation of cutting for s imulating segmented chip formation. For this purpose, special subrouti nes have been implemented and tested. The influence of several paramet ers such as cutting speed, rake angle, and depth of cut has been studi ed. Results of extensive FEM simulations and the comparison with exper imental data are reported.