An ALE three-dimensional model of orthogonal and oblique metal cutting processes

Abstract

An Arbitrary Lagrangian Eulerian (ALE) approach is used in this paper to model continuous three-dimensional orthogonal and oblique steady-state metal cutting processes. The thermomechanical coupled model includes the effects of elastoplasticity, high strain and strain rates, heat generation and friction between the chip and the tool. A thermal-viscoplastic constitutive equation associated with the Johnson-Cook flow law is adopted for the workpiece. A classic Coulomb friction law associated with heat generation and heat transfer is used tomodel the toolchip contact. The model is suitable for predicting thermo-mechanical quantities, chip geometry and the cutting forces from a set of cutting data, material and contact parameters. Cutting experiments and numerical simulations were performed on a 42CD4 steel and comparisons show a reasonable level of agreement.