Title: Finite element modelling of orthogonal cutting: sensitivity analysis of material and contact parameters

Authors: M. Watremez; D. Méresse; L. Dubar; J. Brocail

Addresses: UVHC, TEMPO EA 4542, F-59313 Valenciennes, France ' UVHC, TEMPO EA 4542, F-59313 Valenciennes, France ' UVHC, TEMPO EA 4542, F-59313 Valenciennes, France ' UVHC, TEMPO EA 4542, F-59313 Valenciennes, France

Abstract: This paper presents a finite element model of orthogonal cutting developed with Abaqus/explicit software. An Arbitrary Lagrangian-Eulerian (ALE) formulation is used to predict chip formation, temperature, chip-tool contact length, chip thickness, and cutting forces. This numerical model makes possible qualitative analysis of input parameters related to cutting process and frictional models. A sensitivity allows the identification of significant input parameters (coefficients of the Johnson-Cook law, contact and thermal parameters) and their tolerance limits identification. This study draws to input parameters which have to be determined accurately in order to improve numerical approaches of machining.

Keywords: orthogonal cutting; finite element method; FEM; numerical modelling; sensitivity analysis; machining simulation; chip formation; temperature; chip-tool contact length; chip thickness; cutting force.

DOI: 10.1504/IJSPM.2012.049820

International Journal of Simulation and Process Modelling, 2012 Vol.7 No.4, pp.262 - 274

Received: 16 Apr 2011
Accepted: 04 Jan 2012
Published online: 15 Nov 2014 *

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