Modelling Orthogonal Metal Machining Using Finite Element Analysis

The findings of a research of simulation modelling of orthogonal metal machining using the finite element method and AdvantEdgeTM modelling software are presented in this article. The AdvantEdgeTM is a certified CAE software solution for metal cutting optimization that allows users to examine machining operations in both 2D and 3D settings. By progressively moving the cutting tool from the beginning state to steady-state, the cutting process and primarily cutting forces were simulated, while a geometrical chip-separation criterion based on a critical distance at the tool tip criterion was implemented in the AdvantEdgeTM engine. The study’s goal was to use the finite element approach to estimate cutting forces, chip formation, and temperature at the tool-chip interface in order to model the cutting process. Friction was simulated and executed along the tool-chip contact using a series of finite element simulations. In order to simulate chip detachment from the workpiece, a finite element nodal technique was used. These simulations yielded results that matched experimental findings. Specifically, it was discovered that during machining, the tool-tip zone experiences the greatest plastic strain rate deformation. Maximum temperature increases were discovered to have occurred along the chip-tool contact as a result of energy dissipation owing to plasticity and friction.

Author(s) Details:

Titus Bitek Watmon,
Department of Agricultural Mechanisation & Irrigation Engineering, Busitema University, P.O. Box 236, Tororo, Uganda.

David Xiao,
School of Architecture Computing and Engineering, University of East London, Docklands Campus, E16 2RD, United Kingdom.

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