Finite Element Analysis of Two-Dimensional Metal Cutting Process

Based on LS-DYNA software, metal cutting processes are dynamically simulated by using 2D r-adaptive method. The mechanisms of plastic deformation and chip formation in metal cutting are analyzed. The influences of tool rake angle and friction factor on cutting deformation are analyzed and deformation extent is measured by plastic deformation energy. According to the distribution of stress and strain gotten from the cutting simulation, the generation of compression stress and residual tension stress of the workpiece is analyzed. The distribution of cutting temperature field is also analyzed. The research method can effectively apply to the study of metal cutting theory. It is helpful for the selection of bit tool and technological design of machining.