Prediction of Cutting Forces in Metal Cutting, Using the Finite Element Method, a Lagrangian Approach

The purpose of this study is to introduce the first approach of metal cutting analysis. A Lagrangian based analysis is carried out using the LS-DYNA software. Simulated cutting forces are compared with forces measured by experiments. Series of sensitivity analyses were performed in order to evaluate the FEM (Finite Element Method) model. The model’s sensitivity to changes of different parameters was examined. Experimental measuring of the cutting forces was performed with Kistler dynanometer type 9257BA.The numerical analysis was performed with the explicit finite element code LS-DYNA Ver. 971. rev. 7600.1224. The chip formation was realistically modelled, but the output of forces from the analysis was overestimated when compared with forces measured during orthogonal cutting experiments. The cutting force Fx was overestimated by 104% and the thrust force Fz was overestimated by 60%. An analysis with better agreement between force output from analysis and measured forces has an unrealistic chip formation. In this analysis the cutting force Fx was underestimated by 2.1 % and the thrust force Fz was underestimated by 59.9 %, compared to forces measured during the experiments.