Chip Formation Mechanism Using Finite Element Simulation

Abstract

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 finite element method (FEM) model development. Generally, three types of chips (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 a 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 the evaluation of chip formation in relation to operational parameters, tool settings as well as material properties.

Comparison between finite element analysis and rheological models for chip formation

“…The rheological behavior of machined materials in finite element models is usually described by the Johnson-Cook material model, which allows to consider the properties of workable material as a function depending not only on strain and strain-rate, but also on temperature. However, studies have shown [15] that for the modeling of different forms of chip in the process of cutting, it is necessary to use the Johnson-Cook progressive damage model in conjunction with the Johnson-Cook constitutive material model by using fracture energy as a damage evolution criterion.…”

“…In recent years, FEM has become the main tool for simulating metal cutting processes. It provides appropriate approach to visualize cutting process, because it allows to predict various characteristics of the metal cutting such as cutting forces, temperatures, stresses, chip types and shapes, etc [1,6,15,22].…”

Study of Machining Process of SiCp/Al Particle Reinforced Metal Matrix Composite Using Finite Element Analysis and Experimental Verification

“…Chip morphology can be mainly divided into band-shaped, sawtooth-shaped and nodular chips. Chip formation reported by Mabrouki et al [45] Ozcatalbas et al [46], Dabade and Joshi et al [47,48], Opoz and Chen [39] that it is a combined crumbling/fracture/rupturing process with increasing shear plane angle; however, the partial shearing and tearing along shear plane reported in the work of Joshi et al 1999 [48].…”

“…In this study, the cutting force and chip formation behavior in machining of SiCp/Al containing 50% vol of SiC reinforced particles and 10 μm size was defined along with different machining parameters. In the cutting process, chip formation or chip removal mechanisms play a vital role to understand the machinability characters [39]. The patterns and types of chips in chip formation mechanisms in SiCp/Al material give clues to understand the effect of machining parameters surface quality as well as the influences on the cutting force generation patterns.…”

Effects of High pressure coolant on machining temperature and machinability of AISI 304 stainless steel

“…Above results clearly indicate the effectiveness of HPC in reducing the temperature. This is endorsed to a higher rate of conversion of mechanical to thermal energy by the chip evolution by shearing of solid material [16].…”