Finite Element Prediction of Chip Geometry and Tool/Workpiece Temperature Distributions in Orthogonal Metal Cutting

[+] Author and Article Information
J. S. Strenkowski, Kyoung-Jin Moon

North Carolina State University, Department of Mechanical and Aerospace Engineering, PO Box 7910, Raleigh, NC 27695-7910

J. Eng. Ind 112(4), 313-318 (Nov 01, 1990) (6 pages) doi:10.1115/1.2899593 History: Received June 01, 1988; Revised November 01, 1989; Online April 08, 2008


An Eulerian finite element model is presented that simulates orthogonal metal cutting. The model predicts chip geometry and temperature distribution in the workpiece, chip, and tool without the need for empirical cutting data. With the capability to predict chip geometry, the tool-chip contact length can also be found. Characteristics of the flow field in the vicinity of the tool can also be determined, such as the material velocity, and the stress and strain-rate distributions. It was found that the shear stress occurs over a finite region in front of the tool, rather than a single shear plane. Cutting experiments were performed for aluminum alloy 6061-T6 to validate the model. Good correlation with the model was found based on tool forces and average tool-chip interface temperature measurements.

Copyright © 1990 by The American Society of Mechanical Engineers
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