Dynamic simulation of chip generation and formation in metal cutting

Abstract The two-dimensional finite difference method is applied to model the metal cutting process where the contact interaction between the cutter and workpiece is defined. Lagrange description of motion is used which includes the generation of new surfaces as the workpiece fractures and the chip separates. A cutting path is thus developed and simulated by splitting the nodes of the finite element grid. Special attention is given to the loading process of the cutting tool during the cut-in stage. Chip formation at different times are calculated and presented.