FINITE ELEMENT ANALYSIS OF CHIP FORMATION IN GROOVED TOOL METAL CUTTING

This paper presents the simulation of chip formation in grooved tool cutting using DYNA3D, 3D FEM software for dynamic nonlinear analysis that was used to simulate the orthogonal cutting problem. First, a flat-face cutting tool was employed in the simulation to verify the validity of the FEM model. Next, the same simulation techniques were used to study the effects of different groove geometries on the chip formation process in grooved tool cutting. In the first set of grooved tool simulations, the depth of the groove was constant while the width was decreased. In the second set, the width was constant and the depth was increased. By analyzing the chip flow, chip curl, chip thickness, stress and strain in the chip, the effects of different groove widths and depths on the chip formation process were then discussed.