Browse > Article

A Study on the Effectiveness of Finite Element Method in Orthogonal Cutting  

Youn, Jae-Woong (대구대학교 자동차.산업.기계공학부)
Kim, Hong-Seok (대구대학교 자동차.산업.기계공학부)
Publication Information
Journal of the Korean Society of Manufacturing Technology Engineers / v.19, no.1, 2010 , pp. 42-49 More about this Journal
Abstract
In general, the direct experimental approach to study machining processes is expensive and time consuming, especially when a wide range of parameters are included: tool, geometry, materials, cutting conditions, etc. The aim of this study is to verify the effectiveness of finite element method for orthogonal cutting process by comparing the simulated cutting forces with measured results. Two commercialized finite element codes $AdvantEdge^{TM}$ and Deform-$2D^{TM}$ have been used to simulate the cutting forces in orthogonal cutting process. In this paper, estimated cutting and feed force components are compared with experimental results for different two materials. As a result, it has been found that FEM simulation is effective for understanding and predicting the orthogonal cutting process although some improvements on friction model and remeshing process are needed.
Keywords
FEM simulation; Orthogonal cutting; Cutting force; Cutting condition; Constitutive equation;
Citations & Related Records
연도 인용수 순위
  • Reference
1 Umbrello, D., M'Saoubi, R., and Outeiro, J. C., 2007, "The influence of Johnson-Cook material constants on finite element simulation of machining of AlSI 316L steel," International Journal of Machine Tools and Manufacture, Vol. 47, pp. 462-470.   DOI   ScienceOn
2 Aurich, J. C., and Bil, H., 2006, "3D finite element modeling of segmented chip formation," Annals of the CIRP, Vol. 55, No.1, pp. 47-50.   DOI   ScienceOn
3 Marusich, T. D. and Ortiz, M., 1995, "Modeling and simulation of high-speed machining," International Journal of Numerical Methods in Engineering, Vol. 38, pp. 3675-3694.   DOI   ScienceOn
4 Arrazola, P. J., Ugarte, D., and Dominguez, X., 2008, "A new approach for the friction identification during machining through the use of finite element modeling," International Journal of Machine Tools and Manufacture, Vol. 48, pp. 173-183.   DOI   ScienceOn
5 Ceretti, E., Lazzaroni, C., Menegardo, L., and Altan, T., 2000, "Turning simulations using a three-dimensional FEM code," Journal of Materials Processing Technology, Vol. 98, pp. 99-103.   DOI   ScienceOn
6 Saffar, R. J., Razfar, M.R., Zarei, O., and Ghassermieh, E., 2008, "Simulation of three-dimension cutting force and tool deflection in the end milling operation based on finite element method," Simulation Modeling Practice and Theory, Vol. 16, pp. 1677-1688.   DOI   ScienceOn
7 Bil, H., Kilic, S. E., and Tekkaya, E., 2004, "A comparison of orthogonal cutting data from experiments with three different finite element models," International Journal of Machine Tools and Manufacture, Vol. 44, pp. 933-944.   DOI   ScienceOn
8 Umbrello, D., Filice, L., Rizzuti, S., and Settineri, L., 2007, "On the effectiveness of finite element simulation of orthogonal cutting with particular reference to temperature prediction," Journal of Materials Processing Technology, Vol. 189, pp. 284-291.   DOI   ScienceOn
9 Lee, H. U. and Cho, D. W., 2004, "Calculation of a reference force for feedrate scheduling using FEM analysis of a tool," Proceedings of the Korean Society of Machine Tool Engineers, pp. 416-421.
10 Yen, Y. C., Jain, A., and Altan, T., 2004, "A finite element analysis of orthogonal machining using different tool edge geometries," Journal of Materials Processing Technology, Vol. 146, pp. 72-81.   DOI   ScienceOn
11 Shet, C., and Deng, X., 2000, "Finite element analysis of the orthogonal metal cutting process," Journal of Material Processing Technology, Vol. 105, pp. 95-109.   DOI   ScienceOn
12 Childs, T. H. C., 2006, "Friction modeling in metal cutting," Wear, Vol. 260, pp. 310-318.   DOI   ScienceOn
13 Astakhov, V. P., Osman, M. O. M., and Hayajneh, M. T., 2001, "Re-evaluation of the basic mechanics of orthogonal metal cutting : velocity diagram, virtual work equation and upper-bound theorem," International Journal of Machine Tools and Manufacture, Vol. 41, pp. 393-418.   DOI   ScienceOn
14 Mackerle, J., 1999, "Finite-element analysis and simulation of machining: a bibliography (1976-1996)," Journal of Materials Processing Technology, Vol. 86, pp. 17-44.   DOI