Finite element analysis of orthogonal metal cutting mechanics

The plane-strain finite element method is developed and applied to analyze the orthogonal metal cutting with continuous chip formation. Detailed work-material modeling, which includes the coupling of large strain, high strain-rate and temperature effects, is implemented. The versatility of the finite element method is demonstrated by presenting simulation results to complement the experimental measurements and to gain better understanding of the mechanics of the tool-chip contact and work-material deformation. The contour plots are used to show the distribution of parameters in the deformation zones. The finite difference method is applied to estimate the rate of change of parameters with respect to time. The Eulerian description of the deformation of work-material is also presented to show the variation at seven selected elements, which are expected to pass the deformation zones or go underneath the worn cutting tool.