3D Finite Element Modelling of Segmented Chip Formation

This paper presents a 3D coupled thermo-mechanical finite element model for the simulation of segmented chip formation in metal cutting. For modelling, a commercial finite element code is used. The generation of segmentation is achieved either by element erase with respect to damage or by modification of material flow stress data; both being coupled with continuous adaptive remeshing. A normalized Cockroft-Latham model is utilized as the damage criterion for element erase. Flow stress modification is achieved by using Rhim's material model. Fundamental observations from the simulations are concluded and a guideline for further research is proposed.