Simulation of orthogonal metal cutting by finite element analysis

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2003
Bil, Halil
The aim of this thesis is to compare various simulation models of orthogonal cutting process with each other as well as with various experiments. The effects of several process parameters, such as friction and separation criterion, on the results are analyzed. As simulation tool, commercial implicit finite element codes MSC.Marc, Deform2D and the explicit code Thirdwave AdvantEdge are used. Separation of chip from the workpiece is achieved either only with continuous remeshing or by erasing elements according to the damage accumulated. From the results cutting and thrust forces, shear angle, chip thickness and contact length between the chip and the rake face of the tool can be estimated. For verification of results several cutting experiments are performed at different cutting conditions, such as rake angle and feed rate. Results show that commercial codes are able to simulate orthogonal cutting operations within reasonable limits. Friction is found to be the most critical parameter in the simulation, since good agreement can be achieved for individual process variables by tuning it. Therefore, simulation results must be assessed with all process variables and friction parameter should be tuned according to the shear angle results. Plain damage model seems not appropriate for separation purposes of machining simulations. On the other hand, although remeshing gives good results, it leads to the misconception of crack generation at the tip of the tool. Therefore, a new separation criterion is necessary to achieve both good physical modeling and prediction of process variables.

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Citation Formats
H. Bil, “Simulation of orthogonal metal cutting by finite element analysis,” M.S. - Master of Science, Middle East Technical University, 2003.