FEA modeling and simulation of shear localized chip formation in metal cutting

• Published in: International journal of machine tools & manufacture 1998-09, Vol.38 (9), p.1067-1087
• Main Authors: Xie, J.Q., Bayoumi, A.E., Zbib, H.M.
• Format: Article
• Language: English
• Subjects: Applied sciences; Chip formation; Cutting; Cutting tool; Exact sciences and technology; Finite element analysis (FEA); Machining. Machinability; Mechanical engineering. Machine design; Metal cutting; Metals. Metallurgy; Production techniques; Shear localization
• ISSN: 0890-6955; 1879-2170
• DOI: 10.1016/S0890-6955(97)00063-1

The finite element analysis (FEA) has been applied to model and simulate the chip formation and the shear localization phenomena in the metal cutting process. The updated Lagrangian formulation of plane strain condition is used in this study. A strain-hardening thermal-softening material model is used to simulate shear localized chip formation. Chip formation, shear banding, cutting forces, effects of tool rake angle on both shear angle and cutting forces, maximum shear stress and plastic strain fields, and distribution of effective stress on tool rake face are predicted by the finite element model. The initiation and extension of shear banding due to material's shear instability are also simulated. FEA was also used to predict and compare materials behaviors and chip formations of different workpiece materials in metal cutting. The predictions of the finite element analysis agreed well with the experimental measurements.