Finite element method and its application to cutting processes of stone–plastic composite

This paper investigates the cutting mechanism of stone–plastic composite through orthogonal cutting experiments of finite element simulations. In this work, special attention was given to chip formation and morphology, cutting force, temperature, and surface roughness. Four main types of chip morphology where modeled: cracking chip, element chip, segmental chip, and ribbon chip. The workpiece surface was smoothest in the case of ribbon chips, followed by segmental, element, and cracking chips. Heat generation, depth of cut, and cutting forces were directly proportional to one another. Experimental results and simulation results were in good agreement, confirming that the simulation model developed herein can be used for further investigation of orthogonal cutting processes.Funder: National Natural Science Foundation of China (grant number 31971594); Natural Science Foundation of the Jiangsu Higher Education Institutions of China (21KJB220009); Self-Made Experimental and Teaching Instruments of Nanjing Forestry University in 2021 (nlzzyq202101); Technology Innovation Alliance of Wood/Bamboo Industry (TIAWBI2021-08); International Cooperation Joint Laboratory for Production, Education, Research and Application of Ecological Health Care on Home Furnishing