Numerical modelling of orthogonal cutting: Influence of cutting conditions and separation criterion

Chip formation is a high strain rate process studied with analytical and numerical models. Analytical models have the advantage of a small calculation time, however, they are often based on some assumptions which are difficult to verify. Finite element modelling (FEM) of chip formation process provides more details on the chip process formation, such as plastic strain, strain rate or stress fields. FEM can be used to improve the analytical models' assumptions. There is still a wide dispersion of formulations and numerical parameters adopted in order to obtain accurate results in numerical models. In the Lagrangian approach, it is of crucial importance to establish realistic criteria for element deletion, allowing chip separation from original workpiece. In the arbitrary Lagrangian Eulerian (ALE) formulation no element deletion is needed. This work is focused in modelization of orthogonal cutting. A comparison between both numerical approaches, Lagrangian and ALE is shown. The effects of geometrical parameters, erosion criterion and cutting speed are evaluated. Comparisons between numerical and theoretical results are performed, and the results obtained from the numerical approach are used as an input of analytical model, improving its accuracy