Surface Formation Study Using a 3-D Explicit Finite Element Model of Machining of Gray Cast Iron

Gray cast iron is the material of choice for machine tool structural components. However, since cast iron is a multiphase, anisotropic material it is difficult to machine to a high quality surface finish. To gain insight into the surface formation mechanisms during the machining of gray cast iron an explicit 3-D finite element cutting simulation was developed. To capture the anisotropic nature of gray cast iron flakes were modelled using zero thickness cohesive elements embedded in a pearlite matrix modelled using solid elements. The simulated cutting forces, surface formation, and finished surfaces were examined.