FINITE-ELEMENT SIMULATION OF ORTHOGONAL METAL-CUTTING

The development and implementation of a plane-strain finite element me thod for the simulation of orthogonal metal cutting with continuous ch ip formation are presented. Detailed work-material modeling, including the effects of elasticity, viscoplasticity, temperature, large strain , and high strain-rate, is used to simulate the material deformation d uring the cutting process. The unbalanced force reduction method and s ticking-sliding friction behavior are implemented to analyze the cutti ng process. The deformation of the finite element mesh and comparisons of residual stress distributions with X-ray diffraction measurements are presented. Simulation results along the primary and secondary defo rmation zones and under the cut surface, e.g., the normal and shear st resses, temperature, strain-rate, etc., are presented revealing insigh t into the metal cutting process.