An Explicit Finite Element Model to Study the Influence of Friction during Orthogonal Metal Cutting

* Corresponding author – [email protected] Tel: 414-229-4126 Fax:414-229-6958 ABSTRACT Understanding the tribological aspects of machining processes is essential for increasing the dimensional accuracy and surface integrity of products. In the present investigation, orthogonal metal cutting simulations were performed using an explicit finite-element code, LS-DYNA. In the simulations, a rigid steel cutting tool of different rake angles was moved at different velocities against a stationary aluminum work-piece. A damage material model was utilized for the work-piece to capture the chip separation behavior and the simultaneous breakage of the chip into multiple fragments. In addition, the friction factors at the cutting tool work-piece interface were varied in the contact model. Overall, the rake angle was found to have significant influence on the chip morphology during metal cutting. Moreover, the cutting forces and the discontinuous chip formation process were strongly influenced by the friction and cutting speed.