FINITE ELEMENT MODELING OF OBLIQUE MACHINING USING AN ARBITRARY LAGRANGIAN-EULERIAN FORMULATION

• Published in: Machining science and technology Vol. 13; no. 3; pp. 385 - 406
• Main Authors: Llanos, I., Villar, J. A., Urresti, I., Arrazola, P. J.
• Format: Journal Article
• Language: English
• Published: Philadelphia, PA Taylor & Francis Group 31.08.2009; Taylor & Francis
• Subjects: ALE formulation; Applied sciences; Chip formation; Chromium molybdenum steels; constitutive models; Cutting tools; Exact sciences and technology; FEM; Finite element method; Friction; High strength steels; Machining; Mathematical analysis; Mathematical models; Mechanical engineering. Machine design; oblique machining; sensitivity; Constitutive equation; Austenitic stainless steel; ALE formulation; Variable geometry; Euler Lagrange equation; Chip formation; Machining; Experimental study; Modeling; constitutive models; Operating conditions; FEM; Finite element method; oblique machining; Oblique cutting; Friction; Carbide tool; Cemented carbides; Cutting tool; System identification; sensitivity; Chip tool interface
• ISSN: 1091-0344; 1532-2483
• DOI: 10.1080/10910340903237921

A 3D finite element model (FEM) of the oblique chip formation process was proposed in Abaqus/Explicit™ (v6.5) using an Arbitrary Lagrangian Eulerian (ALE) formulation. The sensitivity of the obtained results to variations of tool geometry angles, tool-chip friction, and cutting conditions was analyzed. Experimental tests were carried out on AISI-4140 steel using uncoated cemented carbide tools under oblique cutting conditions for validation of the FEM results, and a good qualitative agreement between them was obtained. The analysis highlighted the need for a proper identification of the friction on the tool-chip interface for the accurate reproduction of the chip formation process by means of finite element modeling.