FEM Analysis On The Simulation Of The Metal Cutting Process And Its Application In The Research Of Chip Breakers

A Lagrangian finite element model of three dimensional machining is developed to simulate the metal cutting process in this thesis, among which a chip-separation criterion based on the failure character of the material model is the most important. The simulation is performed with a general international finite element-based modeling software. The main work in this thesis can be concluded as follows.1 .The orthogonal cutting model is validated against the state of stress and strain, the form of shear plane and the effect of the tool rake angle on the angle of shear plane.2.The obique cutting model is validated against the relation between the chip flow angle and the tool inclination angle, upward chip curling and sideward chip curling. Therefore, the geometric shapes and the movement of the chip can be predicted accurately.3.The three dimensional cutting model is validated against predictions of cutting forces and chip formation under several cutting conditions. Comparisons of predictions are made against test data to further verify the feasibility of the model.4.1n order to design and optimize the geometry parameters of the chip breaker, some cutting simulations under a variety of parameters are carried through to investigate the effect of the breaker on the geometric shapes of the chip.5.The integrated software is developed to analyze the cutting forces and chip formation. Using the software, the simulation programs are automatically set up, and the cutting forces and chip formation under different machining conditions can be computed expediently.