A study of three-dimensional cutting model

The large deformation, large strain finite element theory, the updated Lagrangian formulation (ULF) and the incremental method are used to develop a 3D elastic plastic analytical model. Besides, it examines the geometric position on the tool tip and twin nodes on the machined surface and the criterion value of strain energy density to serve as the criteria of chip separation during the metal cutting process. In this cutting model, the tool advanced forward step by step. The simulation started from the initial tool-workpiece contact, and ended at the formation of the steady-state cutting force. Finally, a numerical analysis model developed in this paper as applied in the 3D low speed cutting condition of mild steel under the isothermal cutting state to analyse changes in the appearances of workpiece and chip, the distribution of stress and strain, the progress of changes in cutting force, and the preliminary analysis of residual stress. The numerical average steady-state cutting force is compared with the experimental cutting force to verify the developed cutting moder is acceptable.