Meshing strategies in FEM simulation of the machining process

This paper presents some methods of mesh smoothing when using cutting tool inserts with complex geometry of the cutting edge and the rake face. Several sets of meshing parameters are proposed and their influences on the performance of FEM simulation of the cutting process are presented. In addition, both mechanical and thermal characteristics of the cutting process are compared for four groups of meshing parameters. The simulations were carried out for a Ti6Al4V alloy using TiAlN coated carbide commercial cutting tool insert. It was documented that accurate representation of the tool micro-geometry influences the simulation results.