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Abstract
In this paper, the orthogonal metal cutting process is analyzed with the nite element method under plane strain conditions. Frictional
interaction along the toolchip interface is modeled with a modied Coulomb friction law, and chip separation is based on a critical stress
criterion and is simulated using a nodal release procedure. Finite element solutions of temperature, stress, strain, and strain rate elds have
been obtained for a range of tool rake angle and friction coefcient values. Results showing how the toolchip interfacial friction affects the
eld distributions are new and add to the existing knowledge base. This paper also reports the procedure and specic modeling techniques
for simulating the orthogonal metal cutting process using a general-purpose nite element computer code. The ndings of this paper
provide useful insights for understanding and for improving the orthogonal metal cutting process. # 2000 Elsevier Science S.A. All rights
reserved.
Keywords: Finite element simulation; Orthogonal metal cutting; Thermomechanical elds
1. Introduction
In the metal cutting process unwanted material is removed
from a workpiece in the form of chips for producing nished
parts of required dimensions and accuracy. Metal cutting is a
highly non-linear and coupled thermomechanical process,
where the mechanical work is converted into heat through
the plastic deformation involved during chip formation and
also due to frictional work between the tool, chip and
workpiece. During such thermomechanical work conversion, a temperature rise of up to 10008C has been reported in
the literature [1,2].
A thorough understanding of the material removal process
in metal cutting is essential in selecting the tool material and
in design, and also in assuring consistent dimensional
accuracy and surface integrity of the nished product.
The earliest analytical models explaining the mechanics
of metal cutting were proposed by Merchant [3,4], Piispanen
[5], and Lee and Shaffer [6]. These models are known as
shear angle models; they relate the chip shear angle to the
tool rake angle. Kudo [7] introduced curved shearing to
account for the controlled contact between the curved chip
and the straight tool face. These models assumed rigid
perfectly plastic material behavior.
*
Corresponding author. Tel.: 1-803-777-7144; fax: 1-803-777-0106.
E-mail address: deng@engr.sc.edu (X. Deng).
0924-0136/00/$ see front matter # 2000 Elsevier Science S.A. All rights reserved.
PII: S 0 9 2 4 - 0 1 3 6 ( 0 0 ) 0 0 5 9 5 - 1
96
Poisson's
ratio v
Temperature
(8C)
207.0
200.0
190.0
105.0
70.0
50.0
30.0
0.3
0.3
0.3
0.3
0.3
0.3
0.3
20.0
100.0
150.0
200.0
250.0
300.0
350.0
Fig. 2. The nite element mesh used in the orthogonal metal cutting simulations.
97
Table 3
Temperature-dependent thermal expansion coefcient
Flow stress
s (MPa)
Plastic strain
ep (mm/mm)
Temperature
(8C)
Thermal expansion
coefficient a (mm/m K)
Temperature
(8C)
414.0
517.0
759.0
1100.0
409.0
512.0
754.0
1005.0
309.0
412.0
654.0
905.0
259.0
362.0
604.0
885.0
209.0
312.0
554.0
835.0
159.0
262.0
504.0
785.0
0.00
0.01
0.09
0.90
0.00
0.01
0.09
0.90
0.00
0.01
0.09
0.90
0.00
0.01
0.09
0.90
0.00
0.01
0.09
0.90
0.00
0.01
0.09
0.90
20.0
20.0
20.0
20.0
100.0
100.0
100.0
100.0
150.0
150.0
150.0
150.0
200.0
200.0
200.0
200.0
250.0
250.0
250.0
250.0
300.0
300.0
300.0
300.0
12.3
12.7
13.7
14.5
20.0
200.0
400.0
600.0
Fig. 3. Variation of the cutting force with tool-tip displacement for four rake angles and four friction coefcient values.
98
Fig. 4. Contour plots of the temperature rise for the case of rake angle a208 and for four values of the friction coefcient m.
Friction
coefficient ( m)
Cutting speed
(m/s)
Cut depth
(mm)
158
208
258
308
0.0,
0.0,
0.0,
0.0,
2.54
2.54
2.54
2.54
0.254
0.254
0.254
0.254
0.2,
0.2,
0.2,
0.2,
0.3,
0.4,
0.4,
0.4,
0.4
0.6
0.6
0.6
99
f
sf
tf
Fig. 5. Contour plots of the normal stress s11 for the case of rake angle a208 and for four values of the friction coefcient m.
(2)
100
(3)
Fig. 6. Contour plots of the normal stress s22 for the case of rake angle a208 and for four values of the friction coefcient m.
101
DTp Zp
se e_ p Dt
Jcr
Fig. 7. Contour plots of the shear stress s12 for the case of rake angle a208 and for four values of the friction coefcient m.
(4)
102
steady state is reached. On an average 150230 displacement increments are required to reach the steady state
condition, corresponding to about 47 h of CPU time on
a PC with a 400 MHz Pentium chip and running Windows
on NT4.0 operating system.
Fig. 3 shows the variation of the horizontal cutting force
with the tool tip displacement for four rake angles and four
friction coefcient values. For each value of the friction
coefcient m, the cutting force is seen to approach a constant
value as the cutting tool advances, indicating the achievement of a stead-state condition. For each rake angle, the
cutting force is seen to increase as the value of the friction
coefcient increases, as a result of increased resistance due
to friction along the toolchip interface.
Finite element simulation results presented below are taken
after the cutting tool has moved more than 1.5 mm thus they
represent typical steady-state solutions. Because of space
limitations, only results for the case of rake angle a208 are
given. Solutions for other rake angles bear similar features.
3.1. Temperature distribution
The distribution of temperature rise induced by energy
dissipation and local heating is shown in Fig. 4. It is
Fig. 8. Contour plots of the von Mises effective stress se for the case of rake angle a208 and for four values of the friction coefcient m.
103
Fig. 9. Contour plots of the mean stress sm for the case of rake angle a208 and for four values of the friction coefcient m.
104
Fig. 10. Contour plots of the normal strain e11 for the case of rake angle a208 and four values of the friction coefcient m.
105
Fig. 11. Contour plots of the normal strain e22 for the case of rake angle a208 and four values of the friction coefcient m.
with peak strain rates found at the tool tip and near the
turning point of the chip's free boundary. Strain rate contours are also found to exist in the chip along the toolchip
interface, which is often called the secondary shear zone.
However, the distribution of the contours in this zone is
strongly dependent on the friction coefcient m. For the four
friction values shown, the number of contours increases as m
increases from 0.0 to 0.2, and it decreases as m increases
further. The reason for this behavior is the frictional sliding
and sticking along the toolchip interface near the tool tip. It
seems that strain rates are enhanced in the contact region
when m equals 0.2 because of an optimized combination of
deformation and sliding motion, and strain rates are inhibited when m equals 0.6 because of sticking.
4. Summary and conclusions
Successful nite element simulations of the orthogonal
metal cutting process have been carried out using the
106
Fig. 12. Contour plots of the shear strain e12 for the case of rake angle a208 and four values of the friction coefcient m.
values. Steady-state nite element solutions for the temperature rise, stress, strain, and strain rate elds have been
obtained and representative contour plots for these eld
quantities have been presented. Several conclusions can
be drawn from this study and from the nite element
solutions. First, this study demonstrates that it is possible
to carry out sophisticated nite element simulations of
metal cutting processes using advanced general-purpose
commercial codes. Second, the nite element simulations
were able to re-produce experimentally observed phenomena in orthogonal metal cutting, such as the existence of the
primary and secondary shear zones. Third, the nite element
solutions obtained in this study show that friction along
the toolchip interface strongly affects the distribution of
the thermomechanical elds. It is believed that details
afforded by nite element simulations will greatly benet
the engineer in gaining a better understanding of metal
107
Fig. 13. Contour plots of the rate of change of the normal strain e11 for the case of rake angle a208 and four values of the friction coefcient m.
Fig. 14. Contour plots of the rate of change of the normal strain e22 for the case of rake angle a208 and four values of the friction coefcient m.
108
Fig. 15. Contour plots of the rate of change of the shear strain e12 for the case of rake angle a208 and four values of the friction coefcient m.
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109