FINITE ELEMENT SIMULATION OF METAL CUTTING CONSIDERING CHIP BEHAVIOR AND TEMPERATURE DISTRIBUTION

The finite element method was used for simulating orthogonal metal cutting of low-carbon steel. The model predicts chip geometry, behavior of the metal under machining, cutting force values, stress distribution, and temperature distribution along the workpiece and the chip. Separation and the friction action between the chip and tool were simulated using a friction slideline capability. The same technique was applied to the undeformed chip–workpiece interaction zone to simulate the separation between the chip and the workpiece. The model considered the thermal effect and the friction along the tool rake face. Force values predicted from this model were compared with some experimental work for the same material at the same range of cutting speed and show good correlation.