Different chip separation criteria for the FEM simulation of machining were examined. Criterion based on distance between the tool tip and the node located immediately ahead, criterion based on maximum shear stress in the element ahead of the tool tip, criterion based on average maximum shear stress in the shear plane, and criterion based on a combination of distance and stress were investigated. Under conditions of smooth separation of chip from workpiece, simulation results showed that, during steady-state cutting, the type of chip separation criteria did not greatly affect chip geometry, nor distributions of stress and strain. The magnitude of the chip separation criteria also did not significantly affect chip geometry and distributions of stress in the chip but it did affect the chip separation process, distributions of stress in the machined surface, and distributions of effective plastic strain both in the chip and in the machined surface. During the initiation of cutting, neither the geometrical nor physical criteria simulate the machining process correctly. A combination of geometric and physical criteria was also recommended in this study.

1.
Black
J. T.
,
1971
, “
On the Fundamental Mechanism of Large Strain Plastic Deformation—Electron Microscopy of Metal Cutting Chips
,”
ASME JOURNAL OF ENGINEERING FOR INDUSTRY
, Vol.
93
, pp.
507
526
.
2.
Black
J. T.
,
1972
, “
Shear Front-Lamella Structure in Large Strain Plastic Deformation
,”
ASME JOURNAL OF ENGINEERING FOR INDUSTRY
, Vol.
94
, pp.
307
316
.
3.
Black
J. T.
,
1979
, “
Flow Stress Model in Metal Cutting
,”
ASME JOURNAL OF ENGINEERING FOR INDUSTRY
, Vol.
101
, pp.
403
415
.
4.
Brown
S.
, and
Song
H.
,
1992
, “
Finite Element Simulation of Welding of Large Structure
,”
ASME JOURNAL OF ENGINEERING FOR INDUSTRY
, Vol.
114
, pp.
441
451
.
5.
Carroll
J. T.
and
Strenkowski
J. S.
,
1988
, “
Finite Element Models of Orthogonal Cutting with Application to Single Point Diamond Turning
,”
Int. J. Mech. Sci.
, Vol.
30
, No.
12
, pp.
899
920
.
6.
Chandrasekar
S.
,
Wang
S.
, and
Yang
H. T. Y.
,
1990
, “
An Efficient 2-D Finite Element Procedure for Isothermal Phase Changes
,”
ASME JOURNAL OF ENGINEERING FOR INDUSTRY
, Vol.
112
, pp.
352
360
.
7.
Cook
N. H.
,
Finnie
L.
, and
Shaw
M. C.
,
1954
, “
Discontinuous Chip Formation
,”
ASME Transactions
, Vol.
76
, pp.
153
163
.
8.
Engelmann, B. E., and Whirley, R. G., 1991, ISLAND: Interactive Solution Language for An Adaptive Nike Drive—User Manual, Lawrence Livermore National Laboratory, Report UCRL-MA-108721.
9.
Engelmann, B. E., and Hallquist, J. O., 1991, NIKE2D: An Implicit, Nonlinear, Two-Dimensional Finite Element Code for Solid Mechanics—User Manual, Lawrence Livermore National Laboratory, Report UCRL-MA-105413.
10.
Hibbitt, H. D., Karlsson, B. L., and Sorensen, E. P., 1988, ABAQUS Theory and User’s Manual, Version 4.7, Hibbitt, Karlsson & Sorensen, Inc., Providence, RI.
11.
Iwata
K.
, and
Usda
K.
,
1976
, “
The Significance of Dynamic Crack Behavior in Chip Formation
,”
Annals of the CIRP
, Vol.
25
, pp.
65
70
.
12.
Iwata
K.
,
Osakada
K.
, and
Terasaka
Y.
,
1984
, “
Process Modeling of Orthogonal Cutting by the Rigid-Plastic Finite Element Method
,”
ASME Journal of Engineering Materials and Technology
, Vol.
106
, pp.
132
138
.
13.
Lin
Z. C.
, and
Lin
S. Y.
,
1992
, “
A Coupled Finite Element Model of Thermo-Elastic-Plastic Large Deformation for Orthogonal Cutting
,”
ASME Journal of Engineering Materials and Technology
, Vol.
114
, pp.
218
226
.
14.
Klamecki, B. E., 1973, “Incipient Chip Formation in Metal Cutting—A Three-Dimension Finite Element Analysis,” Ph.D. Thesis, University of Illinois at Urbana-Champaign, Urbana, IL.
15.
Komvopoulos
K.
, and
Erpenbeck
S. A.
,
1991
, “
Finite Element Modeling of Orthogonal Metal Cutting
,”
ASME JOURNAL OF ENGINEERING FOR INDUSTRY
, Vol.
113
, pp.
253
267
.
16.
Merchant
M. E.
,
1945
, “
Mechanics of the Metal Cutting Process—I. Orthogonal Cutting and a Type 2 Chip
,”
Journal of Applied Physics
, Vol.
16
, pp.
267
317
.
17.
Mitchum, G. L., 1987, “A Technique for Predicting Chip Formation in Orthogonal Metal Cutting Using A Lagrangian Finite Element Model,” Master Thesis, North Carolina State University, Raleigh, NC.
18.
Oxley, P. L. B., 1989, Mechanics of Machining: An Analytical Approach to Assessing Machinability, John Wiley & Sons, New York.
19.
Park
J. J.
, and
Oh
S. I.
,
1990
, “
Application of Three Dimensional Finite Element Analysis to Shape Rolling Processes
,”
ASME JOURNAL OF ENGINEERING FOR INDUSTRY
, Vol.
112
, pp.
36
46
.
20.
Shaw, M. C., 1984, Metal Cutting Principles, Clarendon Press, Oxford.
21.
Shih
A. J. M.
,
Chandrasekar
S.
, and
Yang
H. T. Y.
,
1990
, “
Finite Element Simulation of Metal Cutting Process with Strain-Rate and Temperature Effects
,”
Fundamental Issues in Machining
, ASME Publication, PED-Vol.
43
, pp.
11
24
.
22.
Strenkowski
J. S.
, and
Carroll
J. T.
,
1985
, “
A Finite Element Model of Orthogonal Metal Cutting
,”
ASME JOURNAL OF ENGINEERING FOR INDUSTRY
, Vol.
107
, pp.
349
354
.
23.
Strenkowski
J. S.
, and
Moon
K.-J.
,
1990
, “
Finite Element Prediction of Chip Geometry and Tool/Workpiece Temperature Distributions in Orthogonal Metal Cutting
,”
ASME JOURNAL OF ENGINEERING FOR INDUSTRY
, Vol.
112
, pp.
313
318
.
24.
Trent, E. M., 1984, Metal Cutting, Second Edition, Butterworths & Co Ltd, London.
25.
Usui, E., and Shirakashi, T., 1982, “Mechanics of Machining—From ‘Descriptive’ to ‘Predictive Theory,” On the Art of Cutting Metals—75 Years Later, ASME Publication PED—Vol. 7, pp. 13–35.
26.
Zhang
B.
, and
Bagchi
A.
,
1992
, “
Finite Element Simulation of Chip Formation and Comparison with Machining Experiment
,”
Computational Methods in Material Processing
, ASME Publication, PED-Vol.
61
, pp.
61
74
.
27.
Zhang, B., and Bagchi, A., 1994, “A Study of Chip Separation in Finite Element Simulation of Continuous Chip Formation,” Submitted for Publication.
This content is only available via PDF.
You do not currently have access to this content.