In the analysis of orthogonal cutting process using finite element (FE) simulations, predictions are greatly influenced by two major factors; a) flow stress characteristics of work material at cutting regimes and b) friction characteristics mainly at the tool-chip interface. The uncertainty of work material flow stress upon FE simulations may be low when there is a constitutive model for work material that is obtained empirically from high-strain rate and temperature deformation tests. However, the difficulty arises when one needs to implement accurate friction models for cutting simulations using a particular FE formulation. In this study, an updated Lagrangian finite element formulation is used to simulate continuous chip formation process in orthogonal cutting of low carbon free-cutting steel. Experimentally measured stress distributions on the tool rake face are utilized in developing several different friction models. The effects of tool-chip interfacial friction models on the FE simulations are investigated. The comparison results depict that the friction modeling at the tool-chip interface has significant influence on the FE simulations of machining. Specifically, variable friction models that are developed from the experimentally measured normal and frictional stresses at the tool rake face resulted in most favorable predictions. Predictions presented in this work also justify that the FE simulation technique used for orthogonal cutting process can be an accurate and viable analysis as long as flow stress behavior of the work material is valid at the machining regimes and the friction characteristics at the tool-chip interface is modeled properly.

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The influence of friction models on finite element simulations of machining

Modelling metal cutting using modern ductile fracture mechanics: quantitative explanations for some longstanding problems

Investigations on the effects of friction modeling in finite element simulation of machining

Simulation of the orthogonal metal cutting process using an arbitrary Lagrangian–Eulerian finite-element method

When metal is removed by machining there is substantial increase in the specific energy required with decrease in chip size. It is generally believed this is due to the fact that all metals contain defects (grain boundaries, missing and impurity atoms, etc.), and when the size of the material removed decreases, the probability of encountering a stress-reducing defect decreases. Since the shear stress and strain in metal cutting is unusually high, discontinuous microcracks usually form on the metal-cutting shear plane. If the material being cut is very brittle, or the compressive stress on the shear plane is relatively low, microcracks grow into gross cracks giving rise to discontinuous chip formation. When discontinuous microcracks form on the shear plane they weld and reform as strain proceeds, thus joining the transport of dislocations in accounting for the total slip of the shear plane. In the presence of a contaminant, such as CCI4 vapour at a low cutting speed, the rewelding of microcracks decreases, resulting in decrease in the cutting force required for chip formation. A number of special experiments are described in the paper that support the transport of microcracks across the shear plane, and the important role compressive stress plays on the shear plane. Relatively recently, an alternative explanation for the size effect in cutting was provided based on the premise that shear stress increases with increase in strain rate. When an attempt is made to apply this to metal cutting by Dineshet al (2001) it is assumed in the analysis that the von Mises criterion pertains to the shear plane. This is inconsistent with the experimental findings of Merchant. Until this difficulty is taken care of, together with the promised experimental verification of the strain rate approach, it should be assumed that the strain rate effect may be responsible for some notion of the size effect in metal cutting. However, based on the many experiments discussed here, it is very unlikely that it is totally responsible for the size effect in metal cutting as inferred in Dineshet al (2001).

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A. Bagchi

Papers

Finite Element Simulation of Chip Formation and Comparison with Machining Experiment