Finite element modeling and validation of chip segmentation in machining of AISI 1045 steel

The finite element (FE) method based modeling of chip formation in machining provides the ability to predict output parameters like cutting forces and chip geometry. One of the important characteristics of chip morphology is chip segmentation. Majority of the literature within chip segmentation show cutting speed (v(c)) and feed rate (f) as the most influencing input parameters. The role of tool rake angle (alpha) on chip segmentation is limited and hence, the present study is aimed at understanding it. In addition, stress triaxiality's importance in damage model employed in FE method in capturing the influence of alpha on chip morphology transformation is also studied. Furthermore, microstructure characterization of chips was carried out using a scanning electron microscope (SEM) to understand the chip formation process for certain cutting conditions. The results show that the tool a influences chip segmentation phenomena and that the incorporation of a stress triaxiality factor in damage models is required to be able to predict the influence of the alpha. The variation of chip segmentation frequency with f is predicted qualitatively but the accuracy of prediction needs improvement.