Two-Dimensional Finite Element Analysis of Turning Processes

Despite crucial efforts invested into computational methods, explicit dynamics simulation of cutting operations may still be unacceptably expensive. Therefore, in many cases a two-dimensional model is considered. Here an overview of the possibilities of two-dimensional simulations is given. For this, simulation and measurement of a straight turning process on AISI 1045 steel is presented. In the numerical analysis, material behavior and its failure was described by Johnson-Cook law, considering damage evolution. Coupled thermo-mechanical model with mass-scaling and adaptive remeshing was built. The numerically obtained cutting force was compared to the measured data. It was found that the forces obtained with simulation and the measured ones show good agreement. Sensitivity analyses were performed to examine the influence of specific parameters on the reaction force. The effect of these parameters is also shown