Microstructure-based FEM Simulation of Metal Cutting

This paper presents a three-dimensional finite element approach to incorporate microstructure into micro cutting simulation based on the concept of a representative volume element (RVE) and constitutive material modeling as well as using the Lagrangian formulation proposed in the implicit FE code Deform 3DTM. Finish broaching, micro milling and micro drilling tests using solid carbide tools with different cutting parameters are performed on ferrite-pearlite two-phase steel AISI 1045 for the verification of the developed 3D multiphase FE computation model regarding chip formation and cutting forces. The developed 3D multiphase FE model is successfully used to predict size effects in micro cutting.