ANALYSIS OF MACHINING PROCESS USING THE FINITE ELEMENT METHOD
The orthogonal machining process is modelled using the finite element method. Starting with fundamental work material properties and cutting conditions, the distribution of flow stress within the chip and workpiece is computed. Plastic and elastic tool-chip friction are accounted for. The distributions of tool-chip contact stresses and the cutting forces obtained in the present analysis agrees well with the experimental results of other researchers. It is postulated that in orthogonal machining, the chip assumes a thickness such that the total strain energy in the workpiece and chip is at a minimum. This hypothesis is confirmed in this study.
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