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Abstract
This study is part of the ongoing research at the Department of Mechanical Engineering of the University of Brescia on FEM simulations
of cutting operations. In recent years, the application of nite element method (FEM) to cutting operations has proved to be effective to
study the cutting process and chip formation. In particular, the simulation results can be used as a practical tool both by researchers and
machine and tool makers to design new tools and to optimize the cutting process.
Several papers are available on two-dimensional simulation of cutting process because the three-dimensional versions of FEM software
required a big effort in computational time. The present work aims to simulate three-dimensional cutting operations. In particular
orthogonal cutting and oblique cutting operations are modeled. The FEM software used for this study is DEFORM 3D. The simulation
results are compared with simulations and experimental data found in literature. A good agreement has been found, conrming the ability
of simulations in predicting chip ow in cutting processes. # 2000 Elsevier Science S.A. All rights reserved.
Keywords: Turning; Three dimensional simulations; Orthogonal cutting; Oblique cutting
1. Introduction
Turning operations are performed to modify shape,
dimension, and surface roughness of a workpiece cutting
away from it several layers of material. The theory of chip
formation and cutting is complex, not only plasticity but also
thermodynamic and mathematical analysis are involved in
this theory [14]. In the recent years, the application of nite
element method (FEM) to cutting operations has been very
helpful to study the cutting process and chip formation. The
computational power of computers and the use of dedicated
software to study plastic deformation of materials make
possible to monitor all the parameters of the working
process. Thus, these software can be used as a practical
tool both by researchers and machine and tool makers. This
is the reason why the application of FEM software to cutting
operations is quite common nowadays and indeed several
papers are available on this topic. Most of these papers deal
with two-dimensional simulation of cutting process because
the three-dimensional versions of FEM software are avail-
0924-0136/00/$ see front matter # 2000 Elsevier Science S.A. All rights reserved.
PII: S 0 9 2 4 - 0 1 3 6 ( 9 9 ) 0 0 3 1 0 - 6
100
101
Fig. 4. Temperature distribution on the surface and inside the tool and the
workpiece.
3. Oblique cutting
Once the capability of DEFORM 3D in making realistic
predictions on cutting processes has been proved, the
next step is the implementation of an oblique cutting model.
This type of cutting operation cannot be modeled in a plane.
It needs to be analyzed in a three-dimensional environment
and this is a good chance to use completely the power of
the three-dimensional software and to test the capability to
give good results even for this complex cutting process
simulation.
102
cut is 0.35 mm and the cutting speed is 0.01 mm/s. The tool
rake angle is 08, the tool inclination angle is 208 and the llet
radius on the cutting edge is 0.1 mm.
The friction
law at the tool/workpiece interface is
p
m 3, m 0.2 and is the effective stress at the
interface.
Fig. 8. Chip geometry after 0.9 mm of tool path: (a) simulations; (b) experiments; (c) Ueda's simulations.
103
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