Analysis of the equivalent plastic displacement influence on chip morphology during the orthogonal cutting process using CEL modeling

Machining is one of the more widely used manufacturing processes in the industry, for this reason, several studies have focused on predicting the effect of variables related to it. In this work, the effect of the equivalent plastic displacement on the orthogonal cutting process, using coupled Lagrangian–Eulerian (CEL) analysis was studied. The workpiece was considered Eulerian solid material to simulate its interaction with the cutting tool and thus, predict material separation and chip morphology. In the present model, the chip morphology was evaluated in terms of the equivalent plastic displacement, segmented chip formation was achieved without the necessity to apply a method of mesh separation and undeleting elements during the calculation solution, which represents an important advantage over the purely Lagrangian method. Additionally, the cutting forces, contact length, angle of the cutting plane, as well as stress, strain, and temperature distribution were obtained.