Abstract
The cutting force in orthogonal cutting of steel AISI 1045 was predicted by applying 2D finite element analysis (FEA) using two methods; (i) Lagrangian (LAG) and (ii) Arbitrary Lagrangian Eulerian (ALE). Johnson-Cook (J-C) models were used for defining plastic and failure properties of simulated materials. The predicted force was validated experimentally by using dynamometer. Comparison held between the simulation methods and experimental work in terms of results accuracy, reading stability, and chip morphology. Furthermore, this study adopted new modeling idea to control the excessive distortion of mesh elements along chip separation line by defining nearly zero damage criterion for these elements. The results demonstrated that LAG and ALE methods could predict the cutting force but with different accuracy, as LAG and ALE results deviated from experimental results with minimum error percentage 3.6% and 0.14% respectively. As well, ALE method showed stable force readings and continues smooth chip during simulation, while LAG method showed unstable force readings and discontinuous realistic chip.
Highlights
Machining processes and their relevant subjects have always great interest for researchers due to their vital role in the industry and economy. Mamalisa et al (2001) stated that researchers initially studied the machining processes in its simplified orthogonal cutting in 1940
Many approaches have been presented for modeling metal cutting, finite element analysis (FEA) is still one of the most reliable and accurate methods
Experimental work was held in two dependant stages; Firstly, the dynamometer was calibrated to be used later for indicating the forces during the machining process
Summary
Machining processes and their relevant subjects have always great interest for researchers due to their vital role in the industry and economy. Mamalisa et al (2001) stated that researchers initially studied the machining processes in its simplified orthogonal cutting in 1940. Wan et al (2019) adopted this method during the FEA of micro milling process to predict the cutting forces, and it helped to control element distortion in the cutting area and the results were accurate and agreed with experiments. As these elements will be deleted from simulation whenever high contact occurred between tool and workpiece without conflicting the chip form or FEA results.
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