Modeling Deformations of the Workpiece and Removal of Material when Turning

During machining mechanical energy is dissipated into heat by frictional processes and plastic deformations of the workpiece material. Workpiece and tool are thereby subjected to thermal and mechanical loads that cause thermal expansions and mechanical deformations. These decrease the accuracy of machining. In order to reduce such deformations, enhanced cutting conditions need to be determined. Finite element (FE) simulations allow for such an optimization prior to actual machining. A validated 3D FE model to determine the temperature distribution and the deformations of the workpiece regarding the cutting condition and the actual tool position is outlined for turning. The continuous removal of material for arbitrary geometries when simulating the temperature distribution and the deformations is considered. This allows for the calculation of the actual workpiece diameter after turning.