Thermomechanical modelling of the tool–workmaterial interface in machining and its implementation using the ABAQUS VUINTER subroutine

Abstract

In this paper the complex thermomechanical behaviour at the tool – workmaterial interface in machining has been analysed. The contact behaviour is formulated in the frame of a Lagrangian Finite Element approach. The thermomechanical laws governing the tool – workmaterial interface in machining have been implemented via the VUINTER subroutine of ABAQUS/Explicit FE code. Using this interface, velocity dependent heat partition coefficient of the frictional heat has been implemented. Numerical results (calculated heat flux transmitted into the tool and cutting force) have been compared to experimental ones for different cutting conditions, which are in good agreement. It is shown that different couples of the heat partition and heat transfer coefficients can give the same heat flux transmitted in the tool. In addition, with the new developed VUINTER subroutine, it is possible to implement any mathematical model governing the friction and heat exchange for simulations of complex contact behaviours. • Metal cutting has been modelled and analysed focussing on the heat exchange at the tool–workmaterial interface. • The contact problem has been formulated in the frame of the finite element method. • Thermomechanical laws governing the tool–workmaterial have been implemented in a finite element code. • Rate-depend heat partition coefficient law has been implemented through the Abaqus VUINTER subroutine. • Comparisons between experimental and numerical heat fluxes and cutting forces have been performed.