A comprehensive review of finite element modeling of orthogonal machining process: chip formation and surface integrity predictions

Abstract

Finite Element (FE) modeling of machining processes has received growing attention over the last two decades. Since machining processes operate at severe deformation conditions, involving very high strain, strain rate, stress, and temperature, the modeling procedure is still a challenging task even with new advanced software and computers. Therefore, most of the published research works were mainly performed for the simplest configuration of machining known as orthogonal cutting, in which a plane strain deformation state is assumed. This configuration leads to reducing the number of elements in the FE model and the computational time of the solution, compared to conventional machining processes (turning, milling, and drilling). Nevertheless, FE modeling of orthogonal turning is still considered as an open-ended subject as most of the phenomena involved in the orthogonal turning process, which also exist in other machining operations, are not fully well understood. The present review article deals with finite element modeling of orthogonal machining process. The paper consists of several related parts. First, the fundamentals of the FE simulation of orthogonal turning process are briefly described. Then, a detailed review on the FE prediction of machining characteristics including chip morphology, cutting forces, cutting temperature, tool wear, and burr formation is provided. Also, the FE prediction of surface integrity characteristics including residual stresses and microstructural changes is discussed. The influence of input model and parameters including thermal, material, and frictional models as well as size and arrangement of elements on machining and surface integrity characteristics are explained as well. Both technical and statistical aspects of the FE simulation of orthogonal turning are treated. Since there is no review paper thoroughly and specifically discussing the methods and findings of the finite element simulation of turning operations, the present article can be used as a reference for researchers who are active and/or interested in this filed.