Prediction of mechanistic cutting force coefficients using ALE formulation

This paper demonstrated the use of an efficient and accurate numerical tool (i.e., FEA) in simulating the cutting process and determining both the average and instantaneous cutting force coefficients. The main advantage of this approach compared to other available methods is that it eliminates the need for experimental calibrations. In this approach, an Arbitrary Lagrangian Formulation was employed in the finite element method simulations. This formulation has been gaining more recognition in structural analysis for its combined advantages of both Lagrangian and Eulerian formulations in a single model. Based on the work of Kline et al. (ASME J Eng Ind 104:272-278, 10), the tool is discretised along the axis into segments and the cutting forces acting on the cutting edge segment are presented in terms of cutting force coefficients. Cutting force coefficients are obtained using the least squares method and cutting force predictions using evaluated coefficients are shown to match experimental results with satisfactory accuracy. © 2009 Springer-Verlag London Limited