Finite Element Simulation of Orthogonal Metal Cutting

[+] Author and Article Information
A. J. Shih

Process Engineering Center—Fuel Systems, Cummins Engine Company, Inc., Columbus, IN 47202-3005

J. Eng. Ind 117(1), 84-93 (Feb 01, 1995) (10 pages) doi:10.1115/1.2803283 History: Received October 01, 1992; Revised February 01, 1994; Online January 17, 2008


The development and implementation of a plane-strain finite element method for the simulation of orthogonal metal cutting with continuous chip 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 during the cutting process. The unbalanced force reduction method and sticking-sliding friction behavior are implemented to analyze the cutting 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 deformation zones and under the cut surface, e.g., the normal and shear stresses, temperature, strain-rate, etc., are presented revealing insight into the metal cutting process.

Copyright © 1995 by The American Society of Mechanical Engineers
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