Finite Element Analysis Of Metal Cutting Process

With the development of science and technology, people has put forwardhigher requirements on metal cutting technology, so the more urgent demandfor high-efficiency, high-precision cutting technology. In this situation, thefinite element simulation of metal cutting has been greatly developed, thislow-cost, more convenient and intuitive simulation technology has a greatreference value of the actual cutting.The chip formation process is analysed, on this basis, two-dimensionalmathematical model of cutting force and three-dimensional milling ball-endmilling force model is built, and two models were compared, that the millingprocess can be approximated with two-dimensionalmodel, thus simplifying theanalysis process.This article uses the ANSYS/LS-DYNA software to establishtwo-dimensional orthogonal metal cutting finite element model, tool materialis WC cemented carbide, the workpiece material is45steel, both can be asdeformable body. The workpiece material using the Johnson-Cook model, thetool is a elastic-plastic body. Using Johnson-Cook fracture criterion to achievethe separation of the chip and workpiece, using self-adaptive grid partitioningtechnique, and the hourglass phenomenon was controlled, the post-processingof analysis results was done with LS-PREPOST software.To discuss the results of the finite element analysis, some conclusions aredrawn as follows:1. Continuous chip is formed with a small cutting speed, discontinuouschip is formed when the cutting speed increases to a certain extent;2. The maximum plastic strain of the chip occurs in the tool chip contactarea, the maximum equivalent stress and maximum stress occurs close to thetip, three kinds of equivalent stress declined from the main deformation zoneto outward.3. The tool equivalent stress is mainly concentrated in the knifepoint andrear face, and wear occurs firstly in the knifepoint and rear face during theprocess of cutting.4. With the cutting speed increases the cutting force also increases, whenthe cutting speed increases to a certain value, the cutting force decreases, tothe high-speed cutting stage; cutting force decreases with the increase of therake angle while increases with the increase of the cutting depth.