Title: Numerical modelling and simulation of orthogonal machining process using FE-code

Authors: G.R. Boob; A.B. Deoghare; P.V. Walke; P.M. Padole

Addresses: Mechanical Engineering Department, G.H. Raisoni College of Engineering, Nagpur-440016, Maharashtra, India ' Department of Mechanical Engineering, NIT, Silcher, Silcher-788010, Assam, India ' Department of Mechanical Engineering, G.H. Raisoni College of Engineering, Nagpur-440016, Maharashtra, India ' Department of Mechanical Engineering, VNIT, Nagpur, Nagpur-440010, Maharashtra, India

Abstract: A numerical model is developed using general purpose finite element code to simulate the orthogonal machining process. Also, computational procedure is proposed for modelling and simulation of metal cutting process. The model is applied to calculate induced residual stresses over surface and sub-surface layers of work-piece. Dynamic explicit time integration technique with Arbitrary Lagrangian Eulerian (ALE) boundary condition is used to simulate metal removal process. Material models have been created using Johnson-Cook flow stress and damage laws. Novelty of current work is that the real time metal cutting behaviour with smooth and continuous chip formation is modelled by modifying material flow stress and damage parameters. Also, it is stated that, accuracy of such simulations is greatly influenced by material models and mesh definition. Findings of this paper provide useful insight about understanding and improving of orthogonal metal cutting process. Model predictions are compared with experimental data of residual stresses under various cutting conditions for validation. The results of simulation are consistent with experimental observations.

Keywords: finite element method; FEM; arbitrary Lagrangian Eulerian; ALE; residual stress; orthogonal machining; numerical modelling; numerical simulation; metal removal rate; MRR; chip formation; metal cutting.

DOI: 10.1504/IJMMM.2015.071997

International Journal of Machining and Machinability of Materials, 2015 Vol.17 No.3/4, pp.370 - 380

Received: 31 May 2014
Accepted: 10 Feb 2015
Published online: 27 Sep 2015 *

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