Finite element simulation of machining process with mesh adaptation

This paper discusses the use of commercial finite element software for physical modeling of metal cutting. Chip separation depends mainly on the proper-ties of the workpiece material and friction conditions. Chip formation results from plastic flow of the material rather than tensile rupture. The code allows the use of stick-slip friction model between the chip and tool surfaces without the need of extra subroutines. Properties of workpiece and tool material can be represented using user determined material constitutive models. Model results address metal cutting characteristics such as chip formation, instantaneous change of cutting forces with time, chip/tool/workpiece interfacial temperature. It also predicts temperature isotherms and residual stress.