Cutting forces and crater wear prediction in orthogonal cutting using two approaches of finite element modeling

Abstract This work deals with plane strain finite element modeling for orthogonal cutting process of carbon steel. The experimental work conducted on a center lathe machine using carbide tools. The main objective was to simulate the cutting process by applying finite element method using computer software (Abaqus/CAE) to predict the cutting forces and crater wear. A comparative study was held between two modeling approaches; Lagrangian approach and Arbitrary Lagrangian‐Eulerian (ALE) approach in terms of force prediction, reading stability and chip form. The results demonstrate that ALE model is more accurate and stable than Lagrangian model, as well ALE chip form is smoother and more reliable. Johnson‐Cook (J‐C) models were utilized to define the plastic and damage properties for the tool and workpiece materials in the finite element program. Finally, this work adopted a methodology to predict crater wear experimentally by using profilometer device. On the other side, the crater wear was predicted from simulation by measuring the contact pressure on tool face. The agreement between the simulation and experimental wear results proves that the ALE model is capable to predict tool wear.