Simulation Research Of Metal Cutting Process By Finite Element Method

In the field of metal cutting, it has an important significance to the investigation of the cutting process. Cutting forces, cutting temperatures and tool wear are the major indexes reflecting cutting process. Especially, cutting forces are widely used. In the cutting process, it directly decides generation of heat and plays a serious role in tool wear and life, precision of work piece, quality of the cut surface and etc. The conventional study begins with the theory and the experiments of metal cutting. In a long time, much more theoretical investigation had been done to find out more precise theoretical formula to calculate the cutting force. However, the large number of interrelated parameters that influence the cutting forces and the complicated cutting process bold back the study. Presently, it is usual way to study the relation between cutting force and cutting parameters through the experiential formula drawn from the orthogonal cutting experiment. However, it can't meet the requirement of predicting and control of cutting force because of its poor universal utilization.Modeling and simulation of cutting processes have the potential for improving cutting tool designs and selecting optimum conditions. Finite element method is becoming one of effective method to research and simulate the cutting processes. The main objective of this study was to develop a FEA model for simulating the cutting process in turning and predict cutting forces, tool stresses and temperatures using finite element analysis. Using FEA software Deform, previously developed flow stress data of the work piece and friction coefficient is used. As an application, machining of 45# steel at 200 HB hardness using uncoated carbide tooling was investigated. Comparisons of predicted cutting forces with measured forces showed similar trends and reasonable agreement, but the predicted cutting force fluctuates when the chips separate from the work piece and tool. Friction between the chip and the tool plays an important role in temperature generation. The highest temperature was predicted at the rake face (around the prime cutting edge) of the tool regardless of cutting conditions. The highest tool stress was predicted at the rake face (around the prime cutting edge) of the tool. The effective stress at back face of the tool is large too.The results indicate that simulation of metal cutting process can predict the main physical phenomena in machining and provide a feasible way to study new materials and new technics. It has a special significance to the manufacture of matel with high efficient and low cost.