Investigation of process parameters in orthogonal cutting using finite element approaches

The cutting force in orthogonal cutting of steel AISI 1045 was predicted by applying 2D finite element analysis (FEA) using two methods; (i) Lagrangian (LAG) and (ii) Arbitrary Lagrangian Eulerian (ALE). Johnson-Cook (J-C) models were used for defining plastic and failure properties of simulated materials. The predicted force was validated experimentally by using dynamometer. Comparison held between the simulation methods and experimental work in terms of results accuracy, reading stability, and chip morphology. Furthermore, this study adopted new modeling idea to control the excessive distortion of mesh elements along chip separation line by defining nearly zero damage criterion for these elements. The results demonstrated that LAG and ALE methods could predict the cutting force but with different accuracy, as LAG and ALE results deviated from experimental results with minimum error percentage 3.6% and 0.14% respectively. As well, ALE method showed stable force readings and continues smooth chip during simulation, while LAG method showed unstable force readings and discontinuous realistic chip.