Finite Element Analysis of Cutting Forces in High Speed Machining
The Finite Element Method (FEM) has proven to be an effective technique to investigate cutting process so as to improve cutting tool design and select optimum cutting conditions. The present work focuses on the FEM simulation of cutting forces in high speed cutting by using an orthogonal cutting model with variant undeformed chip thickness under plane-strain condition to mimic intermittent cutting process such as milling. High speed cutting of 45%C steel using uncoated carbide tools are simulated as the application of the proposed model. The updated Lagrangian formulation is adopted in the dynamic FEM simulation in which the normalized Cockroft and Latham damage criterion is used as the ductile fracture criterion. The simulation results of cutting force components under different cutting conditions show that both the thrust cutting force and the tangential cutting force increase with the increase in undeformed chip thickness or feed rate, whereas decrease with the increase in cutting speed. Some important aspects of modeling the high speed cutting are discussed as well to expect the future work in FEM simulation.
Chengyu Jiang, Geng Liu, Dinghua Zhang and Xipeng Xu
J. Zhao et al., "Finite Element Analysis of Cutting Forces in High Speed Machining", Materials Science Forum, Vols. 532-533, pp. 753-756, 2006