On the finite element modellingof high speed hard turning.pdf

ORIGINALARTICLEONTHEFINITEELEMENTMODELLINGOFHIGHSPEEDHARDTURNINGAGMAMALISTHEMODELSAREVALIDATEDWITHEXPERIMENTALRESULTSFROMTHERELEVANTLITERATUREANDDISCUSSEDADDITIONALLY,OBLIQUECUTTINGMODELSOFHIGHSPEEDHARDTURNINGARECONSTRUCTEDANDDISCUSSEDFROMTHEREPORTEDRESULTSUSEFULCONCLUSIONSMAYBEDRAWNANDITCANBESTATEDTHATTHEPROPOSEDMODELSCANBEUSEDFORINDUSTRIALAPPLICATIONKEYWORDSMACHININGFINITEELEMENTMETHODHARDTURNING1INTRODUCTIONHARDTURNING,AMACHININGOPERATIONUSEDFORTHEPROCESSINGOFHARDMATERIALSSUCHASHARDENEDSTEELS,HASBEENBROUGHTINTOTHEFOREFRONTOFMODERNMETALCUTTINGOPERATIONSWITHTHEINCREASINGDEMANDFORMANUFACTURINGHIGHQUALITYCOMPONENTS,EG,GEARS,SHAFTS,BEARINGS,DIESANDTOOLS,FROMTHESEKINDSOFMATERIALSCUTTINGTOOLSEMPLOYEDINHARDTURNINGAREMADEOFSPECIALIZEDTOOLMATERIALS,SUCHASCUBICBORONNITRITECBN,THATAREABLETOOVERCOMETHEPROBLEMSEXPERIENCEDDURINGTHEPROCESS1THESECUTTINGTOOLSAREIDEALFORMACHININGIRONBASEDMATERIALSATTHESEVERECUTTINGCONDITIONSASSOCIATEDWITHHARDTURNINGTHEYPOSSESSEXQUISITEPROPERTIES,EVENATELEVATEDTEMPERATURES,ALLOWINGFORTHEIRAPPLICATIONATHIGHCUTTINGSPEEDSANDWITHOUTTHEUSEOFANYCUTTINGFLUIDS2BYDRYCUTTINGNOTONLYENVIRONMENTALLYFRIENDLYCHARACTERISTICSAREATTRIBUTEDTOTHEPROCESS,BUTALSOCOSTREDUCTIONCANBEATTAINEDBYOMITTINGBUYINGANDDISPOSALCOSTSOFTHECUTTINGFLUIDS35INADDITIONTHECOMBINATIONOFHARDTURNINGANDHIGHSPEEDMACHININGISPROVEDTOBEVERYADVANTAGEOUSSINCEAGREATREDUCTIONINPROCESSINGTIMECANBEACHIEVED1HARDTURNINGISVERYADVANTAGEOUSFORAWIDESPECTRUMOFAPPLICATIONSANDISALSOCONSIDEREDASANALTERNATIVEFORAVARIETYOFPROCESSES,SINCETHESINGLESTEPSUPERFINISHHARDTURNINGCANREPLACETHEABRASIVEPROCESSES,TRADITIONALLYUSEDASFINISHINGOPERATIONS,ORNONTRADITIONALPROCESSES,SUCHASELECTRICALDISCHARGEMACHININGEDM,INMACHININGHARDPARTS,OFFERINGACCURACYEQUALTOORBETTERTHANTHATPROVIDEDSOFAR,FLEXIBILITYANDCONSIDERABLEMACHININGTIMEANDCOSTREDUCTION47NOTE,HOWEVER,THATHARDTURNINGHASNOTBEENINTRODUCEDINTOMODERNINDUSTRYASMUCHASITSHOULDBE,MAINLYBECAUSEOFPHENOMENASUCHASRAPIDTOOLWEARORCRACKINGINTJADVMANUFTECHNOL200838441446DOI101007/S0017000711149AGMAMALISAMARKOPOULOSDEMANOLAKOSMANUFACTURINGTECHNOLOGYDIVISION,NATIONALTECHNICALUNIVERSITYOFATHENS,ATHENS,GREECEEMAILMAMALISCENTRALNTUAGRJKUNDRKDEPARTMENTOFPRODUCTIONENGINEERING,UNIVERSITYOFMISKOLC,MISKOLC,HUNGARYANDCHIPPINGOFTHECUTTINGEDGEDUETOEXTREMEPRESSUREANDTEMPERATUREIMPOSEDONTHECUTTINGTOOL,WHICHLEADTOPOORMACHININGRESULTS8FURTHERMORE,ASANOVELMACHININGPROCESS,ITNEEDSTOBEFURTHERSTUDIEDSOTHATITMAYBEOPTIMIZEDMOSTRESEARCHWORKISLIMITEDTOEXPERIMENTALRESULTS,BUT,ALSO,THEMODELLINGOFHARDTURNINGCANPROVIDEUSEFULDATATOBETTERUNDERSTANDINGTHEPROCESSNUMERICALMODELLINGAND,ESPECIALLY,THEFINITEELEMENTMETHODFEMHAVEBEENWIDELYUSEDINTHEPASTFORTHEANALYSISANDTHEPREDICTIONOFTHECUTTINGPERFORMANCEINMACHININGOPERATIONSFEMHASBEENAVERYPOWERFULTOOLINTHECUTTINGTECHNOLOGYANDCANBEAPPLIEDTOHIGHSPEEDHARDTURNINGASWELLINTHEPRESENTPAPERFEMISEMPLOYEDINORDERTOSIMULATEDRYHIGHSPEEDHARDTURNING,INVESTIGATINGTHEINFLUENCEOFTHECUTTINGSPEEDONTHEPERFORMANCEOFTHECUTTINGOPERATIONANDPREDICTINGTHECRUCIALPROCESSINGPARAMETERS,SOMEOFTHEMBEINGSOMETIMESVERYDIFFICULTTOBEMEASUREDORCALCULATEDOTHERWISE,EG,TEMPERATUREFIELDSWITHINTHEWORKPIECEANDTHETOOLDURINGTHEPROCESSHOWEVER,HARDTURNINGISARATHERCOMPLEXPROCESS,WITHCUTTINGCONDITIONSTHATAREDIFFERENTFROMCONVENTIONALTURNINGAND,THEREFOREITISDESIRABLETOTAKEINTOACCOUNTSOMESPECIALCHARACTERISTICSFORTHISPURPOSE,THEFEMPROGRAMMETHIRDWAVEADVANTEDGE,WHICHISSPECIALLYDESIGNEDTOSIMULATECUTTINGOPERATIONS,ISUSEDFORTHESIMULATIONOFHARDTURNINGBOTHANORTHOGONALANDANOBLIQUECUTTINGMODELAREPROPOSED2FINITEELEMENTMODELLINGSIMULATIONSOFVARIOUSMACHININGOPERATIONSUSINGTHEFINITEELEMENTMETHODHAVEBEENREPORTEDOVERTHELASTTHREEDECADESINREFERENCES9,10ACOLLECTIONOFSUCHPAPERSCANBEFOUNDTHEFIRSTMODELSTHATAPPEAREDINTHE1970SUSEDTHEEULERIANFORMULATIONFORMODELLINGORTHOGONALCUTTINGINTHISAPPROACHTHEFINITEELEMENTMESHISSPATIALLYFIXEDANDTHEMATERIALFLOWSTHROUGHIT,INORDERTOSIMULATETHECHIPFORMATIONTHECOMPUTATIONALTIMEINSUCHMODELSISREDUCED,DUETOTHEFEWELEMENTSREQUIREDFORMODELLINGTHEWORKPIECEANDTHECHIP,ANDITISMAINLYUSEDFORSIMULATINGTHESTEADYSTATECONDITIONOFTHECUTTINGPROCESSTHEELEMENTSDONOTUNDERGOSEVEREDISTORTION,SINCETHEMESHISAPRIORIKNOWN,BUTTHISFORMULATIONREQUIRESCOMPLEXPROGRAMMINGFURTHERMORE,EXPERIMENTALDATAMUSTBEONHANDPRIORTOTHECONSTRUCTIONOFTHEMODELINORDERTODETERMINETHECHIPGEOMETRYALTHOUGHTHISFORMULATIONISSTILLUTILIZEDBYSOMERESEARCHERS,THEUPDATEDLAGRANGIANFORMULATIONHASBEENPROPOSEDANDISMOREWIDELYUSEDTODAYINTHISAPPROACH,THEELEMENTSAREATTACHEDTOTHEMATERIALANDTHEUNDEFORMEDTOOLISADVANCEDTOWARDSTHEWORKPIECEFORTHEFORMATIONOFTHECHIP,ACHIPSEPARATIONCRITERIONINFRONTOFTHETOOLEDGEISAPPLIEDTHEREAREMANYCRITERIAPROPOSEDSOFARWHICHCANBEGEOMETRICORPHYSICALANDMAYINVOLVEFOREXAMPLEACRITICALDISTANCEBETWEENTHETOOLANDTHEWORKPIECEWHENTHETOOLREACHESTHISCRITICALDISTANCEFROMTHEWORKPIECETHEELEMENTSAHEADOFTHETOOLEDGEAREDIVIDEDANDTHUSTHECHIPISFORMEDOTHERSEPARATIONCRITERIAPERTAINTOCRITICALVALUESOFEG,STRESSORSTRAININORDERTOINITIATETHECHIPFORMATIONANDEVENCRACKPROPAGATIONCRITERIAHAVEBEENREPORTEDFORTHISPROCEDUREADISADVANTAGEOFTHISMETHODISCONNECTEDTOTHELARGEMESHDEFORMATIONOBSERVEDDURINGTHESIMULATIONDUETOTHEATTACHMENTOFTHEMESHONTHEWORKPIECEMATERIAL,THEMESHISDISTORTEDBECAUSEOFTHEPLASTICDEFORMATIONINTHECUTTINGZONEINORDERTOOVERCOMETHISDISADVANTAGECONTINUOUSREMESHINGANDADAPTIVEMESHINGAREUSUALLYAPPLIED,INCREASINGCONSIDERABLYTHEREQUIREDCALCULATIONTIMENEVERTHELESS,THEADVANCESINCOMPUTERSHAVEMADEITPOSSIBLETOREDUCETHETIMENEEDEDFORSUCHANANALYSISTOACCEPTABLELEVELSNOTETHATANARBITRARYLAGRANGIANEULERIANFORMULATIONALEHASALSOBEENPROPOSEDWITHTHEAIMOFCOMBININGTHEADVANTAGESOFTHETWOMETHODS,BUTITISNOTASWIDELYUSEDMOSTOFTHEMODELLINGWORKPUBLISHEDSOFARPERTAINSTO2DMODELSOFORTHOGONALCUTTING,WHILE3DMODELSARERATHERRAREINTHERELEVANTLITERATURETHATISMAINLYBECAUSE,EVENTHOUGH3DCUTTINGISMOREREALISTIC,SINCECUTTINGIS3DINNATURE,ITREQUIRESAMUCHMORECOMPLEXCONSIDERATIONOFWORKPIECEANDCUTTINGTOOLGEOMETRY,CONTACTPROPERTIESAND,OFCOURSEADDITIONALCOMPUTATIONALTIMEINPARTICULAR,THEWORKDEDICATEDTOHARDTURNINGISEVENMORELIMITED1115THEMODELSPROVIDEDBELOWAREDEVELOPEDEMPLOYINGTHETHIRDWAVEADVANTEDGESOFTWARE,WHICHINTEGRATESSPECIALFEATURESAPPROPRIATEFORMACHININGSIMULATIONTHEPROGRAMMEMENUSAREDESIGNEDINSUCHAWAYTHATTHEYALLOWTHEUSERTOMINIMIZETHEMODELPREPARATIONTIMEFURTHERMORE,ITINCLUDESAWIDEDATABASEOFWORKPIECEANDTOOLMATERIALSCOMMONLYUSEDINCUTTINGOPERATIONS,OFFERINGALLTHEREQUIREDDATAFOREFFECTIVEMATERIALMODELLINGTHEADVANTEDGECODEISALAGRANGIAN,EXPLICIT,DYNAMICCODE,WHICHCANPERFORMCOUPLEDTHERMOMECHANICALTRANSIENTANALYSISTHEPROGRAMAPPLIESADAPTIVEMESHINGANDFIG1ORTHOGONALCUTTINGMODELSCHEMATICDIAGRAM442INTJADVMANUFTECHNOL200838441446CONTINUOUSREMESHINGFORCHIPANDWORKPIECE,ALLOWINGFORACCURATERESULTSFORANANALYTICALDISCUSSIONONTHENUMERICALTECHNIQUESUSEDINTHEPROGRAMMEANDACOMPREHENSIVEPRESENTATIONOFITSFUNCTIONSSEEREFERENCE163RESULTSANDDISCUSSION31ORTHOGONALCUTTINGMODELSTHEORTHOGONALCUTTINGSCHEMATICDIAGRAMUSEDINTHEPROGRAMMEISSHOWNINFIG1THEDEPTHOFCUTISPERPENDICULARTOTHEPLANESHOWNINTHEFIGUREANDINTHEPLANESTRAINCASE,ITISCONSIDEREDTOBELARGEINCOMPARISONTOTHEFEEDINTHEPRESENTANALYSISTHEWORKPIECEMATERIALISTHEAISIH13HOTWORKTOOLSTEELANDITSLENGTHISTAKENEQUALTOL3MMTHETOOLMATERIALISCBNANDTHEMODELLINGOFTOOLCHIPINTERFACEFRICTIONISBASEDONCOULOMBSFRICTIONLAW,WITHFRICTIONCOEFFICIENTSETCONSTANTATTHEVALUE05ACUTTINGTOOL,WITH5RAKEANGLE,5CLEARANCEANGLEAND002MMCUTTINGEDGERADIUS,ISUSEDFORTHEANALYSISFURTHERMORE,THEFEEDISTAKENEQUALTOF005MM/REV,WHILETHREEDIFFERENTCUTTINGSPEEDS,NAMELYVC200,250AND300M/MIN,ARECONSIDEREDINFIG2AANDBTHEINITIALMESHANDATYPICALMESHCREATEDAFTERTHETOOLHASCUTHALFOFTHEWORKPIECELENGTHL15MMFORTIMET3104S,FORVC300M/MINRESPECTIVELY,ARESHOWNINTHISFIGURE,THECONTINUOUSMESHINGANDTHEADAPTIVEREMESHINGPROCEDURESCANBEOBSERVEDNOTE,THAT,INFIG2ATHEMESHISDENSERNEARTHETOOLTIP,WHEREDEFORMATIONISABOUTTOTAKEPLACE,WHILEINFIG2BNEWELEMENTSARECREATEDINTHESHEARZONEWHERETHESTRAINRATEISEXPECTEDTOBEHIGHNOTE,ALSO,THATTHEMESHDENSITYINTHECHIP,ESPECIALLYINITSINNERANDOUTERSURFACES,ISALSOHIGHBECAUSEOFTHEDEFORMATIONOFTHEMATERIALINTHISAREAFINERMESHCANFOLLOWTHECURVEOFTHECURLINGMATERIALMORECLOSELYAND,FURTHERMORE,PROVIDEMOREACCURATERESULTSFORTHEVALIDATIONOFTHEPROPOSEDHARDTURNINGMODELEXPERIMENTALRESULTSFROMTHERELEVANTLITERATUREAREUSED,WHERETHEHIGHSPEEDTURNINGOFHARDSTEELTUBES55HRC,INORDERTOACHIEVEORTHOGONALCUTTINGCONDITIONS,ISPERFORMED17INFIG3THEEXPERIMENTALVALUESOFTHETHRUSTFORCEFTANDTHECUTTINGFORCEFCARECOMPAREDTOTHEONESPREDICTEDFROMTHEMODELSFROMTHISFIGUREITCANBESEENTHATTHEEXPERIMENTALANDTHENUMERICALRESULTSAREINAVERYGOODAGREEMENTAND,GENERALLY,THEYFOLLOWTHESAMETRENDSTHRUSTFORCE,WHICHISTHELARGESTFORCECOMPONENT,DECREASESFORINCREASINGCUTTINGSPEED,WHILECUTTINGFORCEINCREASESSLIGHTLYNEVERTHELESS,INALMOSTALLTHECASES,THEFIG2AINITIALMESHANDBMESHATL15MMFIG3NUMERICALANDEXPERIMENTALRESULTSOFTHRUSTANDCUTTINGFORCESFORTHREEDIFFERENTCUTTINGSPEEDSINTJADVMANUFTECHNOL200838441446443NUMERICALVALUESSEEMTOOVERESTIMATETHEEXPERIMENTALONESWHILETHEDISCREPANCIESARELARGERFORHIGHERCUTTINGSPEEDSTHISMAYBEATTRIBUTEDTOTHELARGESTRAINRATESDEVELOPEDDURINGTHEPROCESSTHATALTERSTHEMATERIALBEHAVIOURINSUCHAWAYTHATTHEYCANNOTBETAKENINTOACCOUNTBYTHEMODELORTOINADEQUATEFRICTIONMODELLING,WHICHMEANSTHATAMOREADVANCEDFRICTIONTHEORYNEEDSTOBEMODELLEDNOTE,ALSO,THATITISPOSSIBLE,BESIDESTHECUTTINGANDTHRUSTFORCES,TOEXTRACTFROMTHEPROPOSEDMODELPREDICTIONSFORVALUESTHATITWOULDBEVERYLABORIOUSOREVENIMPOSSIBLETOOBTAINOTHERWISEEXAMPLESOFSUCHCASESARETHETEMPERATUREDISTRIBUTIONINTHEWORKPIECEANDTOOLINTHEFORMOFISOTHERMALBANDSANDTHEVONMISESSTRESSESDEVELOPEDDURINGCUTTINGINFIG4AANDBTHETEMPERATUREFIELDSANDTHEVONMISESSTRESSES,RESPECTIVELY,FORCUTTINGWITHVC300M/MIN,ARESHOWNTHESEFIGURESDEMONSTRATETHEMODELATASTEPOFTHEANALYSIS,SPECIFICALLYFORLENGTHOFCUTL15MM,WHERECUTTINGISWELLINTOTHESTEADYSTATEREGIONTHEFORMOFTHERESULTSISSIMILARFORALLCONDITIONS,EXCEPTOFCOURSETHEMAGNITUDEFROMTHERESULTSOBTAINED,ITMAYBECONCLUDEDTHATTHEMAXIMUMTEMPERATUREINCREASESWITHINCREASINGCUTTINGSPEED,BEING620C,690CAND730CFORTHETHREEDIFFERENTCUTTINGSPEEDSCONSIDEREDTHISMAYEXPLAINTHATTHETHRUSTFORCEDECREASESFORHIGHERCUTTINGSPEED,SINCESOFTENINGOFTHEMATERIALFORHIGHERTEMPERATURETAKESPLACETHEREGIONSTHATAREMOSTLYTHERMALLYLOADEDARETHECHIPANDTHERAKEFACEOFTHETOOL,INTHECHIPTOOLINTERFACECLOSETOTOOLTIP,DUETOTHEPLASTICDEFORMATIONOFTHECHIPANDTHEFRICTIONALFORCESTHEPARTOFTHECHIPTHATISCURLEDAWAYFROMTHERAKEFACEISPROGRESSIVELYCOOLEDDOWNTHESTRESSHASANALMOSTCONSTANTVALUEALONGTHECENTREOFTHESHEARZONE,WHILENEARTHETOOLTIPITHASLOWERVALUESTHISCANBEEXPLAINEDDUETOTHETEMPERATURERISEOFTHISAREAWHICHSOFTENSTHEMATERIALTHEKNOWLEDGEOFTHEMAXIMUMTEMPERATUREANDOFTHEDISTRIBUTIONOFTHETEMPERATUREFIELDSINTHERAKEFACEOFTHETOOLISOFGREATINTERESTBECAUSEHIGHTEMPERATURESINCBNTOOLSARECONNECTEDTOWEARMECHANISMSTHATREDUCETHETOOLLIFEWITHTHENUMERICALRESULTSPROVIDEDBYTHEMODELITISPOSSIBLETOMINIMIZEUNWANTEDEFFECTSANDTOCHOOSESUITABLECUTTINGCONDITIONSINORDERTOOPTIMIZETHEPROCESSANOTHEROPTIONOFTHEPROPOSEDORTHOGONALCUTTINGMODELISTOSIMULATETHEBURRFORMATIONDEVELOPEDWHENTHECUTTINGTOOLEXERTSTHEFULLLENGTHOFTHEWORKPIECETHISCANBEACHIEVEDWHENTHEANALYSISISAPPROPRIATELYEXTENDED,SOTHATTHECUTTINGPATHOFTHETOOLISLONGERTHANFIG4ATEMPERATUREDISTRIBUTIONANDBVONMISESSTRESSESINTHEWORKPIECE,THECHIPANDTHECUTTINGTOOLFIG5BURRFORMATIONANDPLASTICSTRAINOFTHEWORKPIECEANDTHECHIP444INTJADVMANUFTECHNOL200838441446THEWORKPIECELENGTHINFIG5THEBURRFORMATIONINTHEWORKPIECEANDTHEPLASTICSTRAINOFTHEWORKPIECEANDTHECHIP,FORVC300M/MIN,CANBESEEN32OBLIQUECUTTINGMODELSTHE2DMODELSPRESENTEDSOFARAREMOREPOPULARINTHEMODELLINGOFCUTTINGOPERATIONSSINCETHEYARERELATIVELYSIMPLEANDTHEYCANOFFERACCEPTABLEACCURACYNEVERTHELESS,ORTHOGONALMACHININGISANIDEALREPRESENTATIONOFCUTTING,WHERETHECHIPDEFORMSINAPLANEINREALITY,CHIPDEFORMATIONINTURNINGTAKESPLACEINALLTHETHREEDIMENSIONSTHE3DMODELSPROPOSEDSOFARINTHELITERATUREAREDIFFERENTFROMTHECLASSICALOBLIQUECUTTINGMODELAPPROACH14,15HOWEVER,ITISTHISAPPROACHTHATWILLBEPRESENTEDINTHISWORKSINCEMUCHEXPERIENCEHASALREADYBEENACCUMULATEDFROMITSAPPLICATIONTOSIMILARPROBLEMS,ADEQUATELYHANDLING3DMODELLINGWITHTHEFINITEELEMENTMETHODFORTHESIMULATIONTHESAMESOFTWARE,ASPREVIOUSLY,ISUSEDFURTHERMORE,ALLTHEPARAMETERSOFTHEWORKPIECEANDTHECUTTINGTOOL,ASWELLASTHECUTTINGCONDITIONSARETHESAMEASINTHEMODELSOFTHEPREVIOUSPARAGRAPH,FORCUTTINGSPEEDVC300M/MINADDITIONALLY,ABACKRAKEANGLEOF20OISGIVENTOTHETOOLTHEPROPOSEDOBLIQUECUTTINGMODELFORDRYHIGHSPEEDHARDTURNINGCANPROVIDE,ASINTHECASEOF2DMODELLING,MUCHUSEFULDATAINFIG6THETEMPERATUREFIELDSINTHEWORKPIECE,THECHIPANDTHETOOLCANBEOBSERVEDINTHESAMEFIGURE,THEPOSITIONOFTHECUTTINGTOOL,RELATIVETOTHEWORKPIECE,CANALSOBESEEN,EXPLAININGTHEFORMOFTHECHIPCREATEDTHECURLINGOFTHECHIPCANBEBETTEROBSERVEDINFIG7,WHEREAREARVIEWOFTHEWORKPIECEINTHESAMETIMESTEPCANBESEENADDITIONALLY,INTHESAMEFIGURE,THECUTTINGTOOLISOMITTEDSOTHATTHETEMPERATURESATTHELOCATIONWHERECUTTINGTAKESPLACECANBEOBSERVEDNOTETHATINTHESEMODELSMOREELEMENTSTHANTHE2DMODELSDESCRIBEDSOFARAREREQUIRED,WITHCOMPUTATIONALTIMEBEINGAPPROXIMATELY10TIMESMORETHECOMPUTATIONALTIMEREQUIREDFORA3DMODELONAMODERATEPCISOVER100HOURSEVENTHOUGH3DMODELSPROVIDEMOREINFORMATIONBEINGMOREREALISTIC,THEYPRESENTTHISDRAWBACKTHATMAKESTHEMLESSPRACTICALTHAN2DMODELS4CONCLUSIONSSUMMARIZINGTHERESULTSREPORTEDABOVE,ONEMAYCONCLUDETHATHARDTURNINGISCONSIDEREDTOBEANEWMACHININGPROCESSTHATHASMANYADVANTAGESINCOMPARISONTOOTHERPROCESSESINTHEMACHININGOFHARDENEDSTEELSESPECIALLY,WHENHARDTURNINGISPERFORMEDATHIGHSPEEDS,ITISEVENMOREADVANTAGEOUS,OFFERINGREDUCEDMACHININGTIMEANDCOSTCHARACTERISTICSTHEFINITEELEMENTMETHODHASBEENEXTENSIVELYUSEDFORMODELLINGMACHININGOPERATIONSINTHEPASTTHISMETHODISALSOUSEDINTHEPRESENTPAPERANDTHECOMMERCIALFEMPROGRAMMETHIRDWAVEADVANTEDGEPROGRAMMEISEMPLOYEDWITHTHEAIDOFTHISSPECIALISEDSOFTWARE,SIMULATIONOF2DORTHOGONALCUTTINGAND3DOBLIQUECUTTINGMODELSAREPROVIDEDTHEORTHOGONALCUTTINGMODELSPROVIDERESULTSSUCHASCUTTINGANDTHRUSTFORCESWHICHWERECOMPAREDTOEXPERIMENTALRESULTSFROMTHERELEVANTLITERATUREHOWEVER,OTHERRESULTSSUCHASTHEWORKPIECEANDTOOLTEMPERATURES,STRESSANDSTRAINCANBEPREDICTEDTHESERESULTSWOULDBEVERYLABORIOUSANDTIMECONSUMINGTOBEOBTAINEDOTHERWISETHELATTERRESULTSCANBEUSEDFORTHETHEORETICALSTUDYOFTHEPROCESSASWELLASTOBECONNECTEDWITHCERTAINPHENOMENAAPPEARINGINTHISKINDOFMACHININGSUCHASTOOLWEARWHICHINTURNAFFECTSWORKPIECESURFACEINTEGRITYADDITIONFIG6TEMPERATURESPREDICTEDBYTHEOBLIQUECUTTINGMODELFORHARDTURNINGFIG7REARVIEWOFTHEMODELINTJADVMANUFTECHNOL200838441446445ALLY,THEBURRFORMATIONINORTHOGONALCUTTINGWASMODELLEDANDPRESENTEDTHE3DOBLIQUECUTTINGMODELSREPRESENTASITUATIONWERETHECHIPDEFORMSNOTINPLANEASINTHEIDEALCASEOFORTHOGONALCUTTINGBUTINALLTHREEDIMENSIONSAMOREREALISTICAPPROACHIS,THUS,PROVIDEDTHEPROPOSEDOBLIQUECUTTINGMODELSAREINAPOSITIONOFPROVIDINGTHESAMEDATAASTHE2DMODELS,BUTALSOSOMEADDITIONALINFORMATION,EG,FORTHE3DFORMATIONOFTHECHIPNEVERTHELESS,THESEMODELSAREMORECOMPLICATEDANDREQUIRETHEUSEOFMUCHMOREELEMENTSINCREASINGTHISWAYTHEEFFORTANDTHECOMPUTATIONALTIMEREQUIREDFORTHEANALYSISFROMTHEANALYSISITCANBECONCLUDEDTHATTHEPROPOSEDMODELSAREPRACTICAL,SINCEONLYAMINIMUMAMOUNTOFEXPERIMENTALWORKISNEEDED,ANDPRODUCERELIABLERESULTS,ALLOWINGFORINDUSTRIALUSEINPURSUEOFOPTIMALPRODUCTIONREFERENCES1TRENTEM,WRIGHTPK2000METALCUTTING,4THEDNBUTTERWORTHHEINEMANN,WOBURN,MA,USA2TNSHOFFHK,ARENDTC,BENAMORR2000CUTTINGOFHARDENEDSTEELANNALSOFTHECIRP49/25475663BYRNEG,SCHOLTAE1993ENVIRONMENTALLYCLEA