Applications of Plane Strain Finite Element Analysis in Metal Cutting for Powertrain Machining

Paper #:
  • 2017-01-1334

Published:
  • 2017-03-28
Abstract:
Despite the significant advances made in modelling of metal machining processes, there fails to be a wide scale adoption of finite element analysis (FEA) for metal cutting in industrial applications. In part this is due to the complexities and computational expense of simulating complex 3D cutting. For related reasons most academic work has focused on orthogonal cutting, which is of limited industrial interest. This paper outlines how to efficiently utilize results from orthogonal cutting simulations to predict industrially relevant performance measures. In this paper 2D FEA cutting models are used to simulate a range of feed, speed and rake angles. Cutting force coefficients are then fit to the predicted cutting forces. Forces for 3D cutting geometries are then calculated using these coefficients. These forces are then used as an input to 3D FEA models of the part and fixture, in order to predict part behavior during cutting. This approach allows for 3D part deflections to be calculated, without the computational expense and uncertainty of a 3D cutting model. Since this approach does not require experiments to define the cutting force coefficients, the approach is well suited to the early design stages of components, when physical parts and tooling are not yet available. Compared to a complete 3D cutting model a significant reduction in simulation time is shown as well as much better correlation to experimental values. Results are shown to be very comparable to the empirical approach.
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