Chip formation mechanism using finite element simulation

Prediction of chip form produced during machining process is an important work when considering workpiece surface creation and possible damage caused by chips generated during machining. The paper presents a set of new results of cutting chip formation from the latest FEM model development. Generally three types of chips, namely, continuous, serrated and discontinuous chips, are generated during metal machining. The formation of these three types of chips is investigated in relation to various influential factors, such as rake angles and depth of cuts. Progressive damage model with damage evolution criterion is employed into the FEM model to reduce mesh dependency. It has been demonstrated that finite element simulation is a good tool for evaluation of chip formation in relation to operational parameters, tool settings as well as material properties