Metal cutting mechanics, finite element modelling

This chapter presents a short analysis of the basics of traditional metal cutting mechanics, outlining its components and the basics of finite element modelling (FEM) of the metal cutting process. Based on a previously proposed definition of metal cutting, advanced metal cutting mechanics considers the power spent in metal cutting as the summation of four components: the power spent on the plastic deformation of the layer being removed, the power spent on the tool-chip interface, the power spent on the tool-workpiece interface, and the power spent in the formation of new surfaces (cohesive energy). Energy partition in the cutting system and the relative impact of the parameters of the machining regime are discussed. Analyzing the basics of FEM and presenting examples, this chapter considers the errors in such modelling and their major sources. It points out the importance of the selection, verification and validation of the physically justifiable model.