FINITE ELEMENT SIMULATION OF CHIP FORMATION

Grinding process is a derived form of cutting processes, in which the cutting tool is relatively small and has not well defined geometric shape as well as oriented with extremely high rake angle to workpiece. Considering single grit cutting process occurred in grinding, it can be associated with the orthogonal cutting process in some aspects. In metal cutting process, chip formation is a phenomenon needed to investigate in detail to explore the machining characteristic of materials. In this work, chip formation process has been performed in Abaqus/Explicit. Two different Mises plasticity model (with Johson-Cook and isotropic hardening) are applied in conjunction with the suitable damage laws. Therefore, continuous chip formation is simulated. Stress and force variation has been analyzed. A few different simulations have been performed as to find the suitable model and technique considering remeshing, material constitutive model, elasticity and plasticity, damage initiation criterion, contact properties.

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