Computational and Evaluation of Orthogonal Metal Cutting Process Using Ale Method

The commercial success of a new product is influenced by the time market product. New cutting inserts are developed by time consuming trial and error process guided by the empirical knowledge of the mechanical cutting process. One of the stateof-the-art efforts in manufacturing engineering is the finite element simulation of the mechanical cutting process. These computational models would have greater values in increasing the understanding of the cutting process and in reducing the number of experiments which traditionally are used for the tool design, process selection etc. This project work focuses on the development of a finite element model for the cutting process, which can predict chip formation, cutting forces and stress strain distribution on the work piece. A dynamic explicit time integration technique with Arbitrary Lagrangian Eulerian (ALE) adaptive meshing finite element method (FEM) is employed to simulate the model. The Johnson-Cook material model is used to describe the work material behavior. Two basically different modeling approaches have been used for the chip separation, geometrical and physical model. The automatic control of the mesh quality is managed by using the ALE. The implemented combined penalty-barrier contact algorithm has been found to be efficient in conjugation with the adaptive meshing.