A thermoelastic-plastic large deformation model for orthogonal cutting with tool flank wear—Part I: Computational procedures

Abstract A coupled model of a thermoelastic-plastic material undergoing large deformation during orthogonal cutting with a pre-honed land simulating tool flank wear is constructed. A coupled method in which deformation is analysed using the finite element method and transient heat transfer with a finite difference method including special numerical techniques is developed. The cutting tool is incrementally advanced forward in a step-by-step process from the incipient stage of tool-workpiece engagement to a steady state of chip formation. A chip separation criterion based on the critical value of the strain energy density is introduced into the analytical model and a scheme of twin node processing is presented for chip formation in this model. A numerical technique of gradually reducing displacement was developed to deal with the generation of new nodes of contact with the tool flank. Convergence criteria and techniques are also developed in this paper.

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