Finite element simulation of chip formation in orthogonal metal cutting

A coupled thermo-mechanical model of plane-strain orthogonal metal cutting with continuous chip formation is presented using the commercial implicit f inite element code MARC. The flow stress of the work-material is taken as a function of strain, strain-rate and temperature in order to take into acco unt the effect of the large strain, strain-rate and temperature associated with cutting on the material properties. The cutting process is simulated f rom the initial to the steady-state of cutting force, by incrementally adva ncing the cutting tool, while a geometrical chip-separation criterion, base d on a critical distance at the tool tip regime, is implemented into the MA RC code by employing the rezoning procedure. The shape of the chip and the stress, strain and strain-rate distributions in the chip and workpiece, as well as the temperature fields in the workpiece, chip and tool, are determi ned. The calculated cutting forces are compared with published experimental data and found to be in good agreement, validating, therefore, the propose d FE model. (C) 2001 Elsevier Science B.V. All rights reserved.