Preliminary FEM modeling of orthogonal turning

The purpose of this thesis is to develop a computational model used for studying the effects of changing parameters involved with machining. The information given by the FEM model will ultimately be used in the determination of tool wear. The development of such models are important in the minimization of expensive and time consuming machining experiments for predicting tool life. Finite element method modeling was developed for the computational models for machining of an aluminum alloy (AL319T6) during orthogonal cutting. The model consisted of 2-D, plane strain, reduced integration, and four-nodes bilinear elements with hourglass stiffness control. A ductile fracture criterion based on predetermined distance from the tool tip was applied in ABAQUS to describe crack growth in the chip formation. Chip formation in metal cutting is a large deformation problem. Large deformation of the finite elements was corrected by remeshing the model as needed. The chips predicted by the computational machining model were similar to continuous chips formed in metal cutting. The specific parameters analyzed were the curvature of the formed chip and the reaction forces in the tool during cutting process. Chip curvature and reaction forces are dependant on the rake angle of the tool and the cutting velocity. Curvature of the chip plays a major role in breaking the continuous chip. Reaction forces are important in the design of machine tools and other areas.