The use of volume of solid (VOS) approach in simulating metal cutting with chamfered and blunt tools

A new volume of solid (VOS) method is proposed for simulating metal cutting applications. The method utilizes the Eulerian finite element formulation along with a numerical scheme to calculate volume of solid fractions in empty elements or cells. The method is shown to overcome problems with existing finite element formulations and may easily track and model the unconstrained flow of the material at free boundaries. As a sample application, the method is used to study the effect of introducing a chamfer angle to the tool or using a blunt (worn) tool on some of the process variable and on the cutting forces both in the cutting and thrust directions. The results of the VOS method are compared to similar results obtained using the arbitrary Lagrangian–Eulerian approach and to experimental results that were performed for one sharp and two chamfered tools.