A fully coupled thermomechanical two-dimensional simulation model for orthogonal cutting: formulation and simulation

In this paper a fully coupled thermomechanical two-dimensional simulation model for orthogonal cutting is presented. The model is based on the arbitrary Lagrangian–Eulerian formulation with the remeshing technique. The material model used for the workpiece material includes Johnson–Cook plasticity, and as the chip separation criterion the Johnson–Cook damage law is employed. The different friction zones are modelled by the Coulomb friction law with a maximum limit for the friction. The capability of the model to represent the cutting process realistically is validated by performing simulations for different feed depths. The model is validated by comparison of the simulated values and measured experimental data for several different important process parameters, such as the feed force, the cutting force, the chip thickness ratio, the relative deformation widths, and the temperature distribution. The results from the simulations showed very good agreement with the experimental data.