FEM Simulation Of The Three-dimension Metal Cutting

In the field of metal cutting, it has an important significance to the investigation of the cutting process. The existed researches show that it is effective to investigate cutting process using numerical method. Therefore, in this paper, a systematic investigation on metal cutting process has been carried out using 3D coupled thermal-mechanical FEM numerical simulation.In this paper, the finite element models of metal cutting were first discussed systemically. A 3D finite element model under coupled thermo-mechanical effects of metal cutting has been developed based on rigid-viscoplastic FEM, and some key technologies have been confirmed, including material model, chip separation criteria, meshing, the contact friction model, abrasion model, contact boundary, etc. Based on the platform of finite element software DEFORM-3D, the processes of metal cutting were simulated successfully. The laws of distribution have been disclosed for equivalent strain field, temperature field and tool wear. The model has been validated by simulation results to be reliable.The influence of main process parameters on chip distortion, cutting force, cutting temperature and tool wear have been disclosed. By comparing with the theoretical analysis, the feasibility of the numerical simulation was validated, the obtained results may provide a guide to optimizations of process parameters, control of the cutting quality and tool design.