Finite element analysis of orthogonal metal machining.

Abstract

This paper presents simulation result of a study on the process of orthogonal metal machining with the finite element method using AdvantEdgeTM software. The software is a validated CAE software solution for the optimization of metal cutting, enabling users to analyze machining processes in 2D and 3D environments. The cutting process and mainly the cutting force is simulated from the initial state to the steady-state, by incrementally advancing the cutting tool, while a geometrical chip-separation criterion, based on a critical distance at the tool tip criterion was implemented by simulating in the AdvantEdgeTM engine. A series of finite element simulations were performed in which friction was modelled and executed along the tool-chip interface. A finite element nodal procedure was adopted in simulating chip separation from the workpiece. The results of these simulations were consistent with experimental observations. Specifically, it was found out that tool tip undergoes the largest plastic strain rate. Meanwhile, the maximum temperature rise which was a product of energy dissipation due to plasticity and friction occurred along the chip-tool interface. Keywords: Finite Element, Chip Formation, Critical Distance, Nodes, Simulation, Metal Machining.