A new procedure to increase the orthogonal cutting machining time simulated

International audienceSurface integrity is extremely affected by manufacturing processes conditions especially the evolution of cutting tool performance. Manyresearchers, in steel machining field, focused their works on the elaboration of models predicting tool wear combining both numerical andexperimental approaches.Most of published numerical cutting models simulate the chip formation for a few micro to millisecond time periods. For that, allcorresponding experimental tests, needed for the model validation, are usually carried-out in special time conditions which is not reflectingindustrial situations. Indeed, the latters are characterized by tool wear whose evolution can affect extremely cutting force levels and the finalworkpiece integrity.In this context, the main purpose of the proposed research work is to develop a FEM model, based on the commercial code ABAQUS©, tosimulate wear phenomenon of tool insert in the case of orthogonal cutting operation. The present research exposes a lagrangian approachsimulating the chip formation in the case of AISI 4140 machining. A strategy that aims to reach high machining time simulated with moderatecomputational time is presented. It is based on ensuring the thermal continuity of the tool from one calculation to another. A considerable gainof calculation time is achieved comparing to the most common models developed on ABAQUS©