Three-dimensional thermo-elastic-plastic coupled FEM simulations for metal oblique cutting processes

Metal oblique cutting processes are modelled by the three-dimensional finite element method (FEM) with thermo-elastic-plastic coupling. The model refers to some key aspects, including thermo-mechanical coupling effects for material flow in cutting and the rigid material model with thermal effects for tools. At the tool-chip and tool-workpiece interfaces, a shear friction model is involved. Authors simulated the machining process of the workpiece, chip, and tool from the incipient state to steady state. The detailed calculated results are presented, including the chip's geometric shape and its evolution, the stress, strain, and temperature distribution in the workpiece and chip, as well as the variations of cutting forces at four different tool inclination angles. (c) 2004 Elsevier B.V. All rights reserved.