Numerical simulation of orthogonal cutting using the material point method

A material point method simulation of orthogonal cutting that can simulate cutting into steady-state chip curling is described. The modeling used ductile fracture mechanics with a cohesive zone in the cutting path. Robust simulations required a new mechanism to damp kinetic energy artifacts associated with dynamic crack propagation. The simulations displayed two regimes-crack-tip touching, where the tool reaches the crack tip, and plastic bending, where the tool is separated from the crack tip by a gap. The simulations were compared to analytical models that were revised to account for rubbing forces and hardening laws.