SERRATED CHIP PREDICTION IN FINITE ELEMENT MODELING OF THE CHIP FORMATION PROCESS

Abstract

A 2D Finite Element Model set up using the Arbitrary Lagrangian Eulerian (A.L.E) formulation proposed in Abaqus/Explicit (v6.4) is employed to predict serrated chip formation during cutting process. No artificial criterion is employed to create the chip or to initiate serrated chip formation. The sensitivity of serrated chip prediction to numerical and process parameters is analyzed in this paper. Experimental tests in orthogonal cutting conditions on machining of AISI-4140 with coated and uncoated cemented-carbide inserts were carried out to validate numerical results. They showed significant influence of cutting speed and rake angle on the serrated chip phenomena. The comparison between numerical and experimental results showed a good qualitative agreement and underlined the outstanding influence of the element dimensions employed in Finite Element Modeling (F.E.M.) tests.

Keywords:

• Chip formation process
• Cutting
• Finite element method
• Machining
• Serrated chip

ACKNOWLEDGMENTS

The authors would like to thank the Basque and Spanish Governments for the financial support given to the projects: MARGUNE (code IE03-107) and INVERMODEL (DPI2003-09676-C02-01 and PI 2004-9) and Maquimodel (DPI2006-15502-C02-01). Authors also thank the reviewers for their input and comments.