An ALE formulation for the solution of two-dimensional metal cutting problems

Abstract This work concerns the development of numerical methods for efficient and reliable computer simulations of cutting operations. A finite element (FE) code, based on an arbitrary Lagrangian–Eulerian (ALE) formulation has been developed. The ALE formulation allows a natural treatment of the cracking of work material. In addition, large strains do not cause problematic element distortions and by using flow boundary conditions only a small part of the workpiece in the vicinity of the tool tip needs to be modeled. A few test simulations show promising results and the ALE formulation seems numerically robust.