Advanced Materials Research Vols.

821-822 (2013) pp 1410-1413 Online: 2013-09-18

© (2013) Trans Tech Publications, Switzerland
doi:10.4028/www.scientific.net/AMR.821-822.1410

Finite element simulation of the orthogonal cutting based on Abaqus

LIU Xuebin1,2, a*, WANG Xibin1, b, LI Chongning2,c and DENG Sanpeng2,d

1
Key Laboratory of Fundamental Science for Advanced Machining, Beijing Institute of Technology,
Beijing 100081, China
2
Tianjin Key Laboratory of High Speed Cutting &Precision Machining(TUTE), Tianjin University of
Technology and Education, Tianjin, china
a b c
ewinding@163.com, Wangxibin@bit.edu.cn, Lichongning@tute.edu.cn,
d
Dengsanpeng@yeah.net

Keywords: Abaqus, Cutting process, orthogonal cutting.

Abstract. In view of orthogonal cutting, finite element simulation geometry is built. the friction
model, thermal conduction model and chip separation model are established between chip and tool
using Abaqus which is a finite element analysis software. Through a specific example,
two-dimensional finite element model have been established, simulating the cutting process stress
distribution of the work piece surface is also obtained during processing. While simulation analyzes
the relationship between the rake angle and shear angle, the results of simulation and experiment are
basically the same, thus further verify the credibility of Abaqus simulation results on orthogonal
cutting, and the feasible is also proved of obtaining cutting data by the use of Abaqus simulation
cutting process.

Introduction
With the rapid development of computer technology, finite element analysis method has been widely
used, people are increasingly concerned about the finite element analysis in the field of application
and development of cutting. By computer simulation technology, a variety of cutting theory are
verified by simulation, cutting data obtained by experiments can be verified, the channel obtaining the
cutting data will be to extend. Cutting data are usually derived from the manufacturing practice or
experiment study, which not only spend a lot of human and financial resources, but also the result can
only be empirical formula. And experimental studies are not able to meet the needs of the
development of cutting technology for higher requirements. Cutting data obtained by the
manufacturing practices, have high credibility, but belong usually commercial secret because of
involving economic efficiency of enterprises, and it is difficult for the outside people to get.
Therefore, it is greatly restricted to obtain the cutting data. With cutting theory validated by the finite
element model , once it is true that the simulation results are consistent with the experimental results,
we can predict a large number of cutting data by using the finite element simulation.
Orthogonal cutting and ABAQUS
Orthogonal cutting, also known as rectangular cutting , tool cutting edge inclination angle of the tool
cutting edge is equal to 0 while at right angles to the cutting edge and the cutting speed. Cutting angle
case, assuming that the cutting width is much greater than the cutting thickness, and the generation of
chips is continuous, deformed state of the cutting edge is substantially the same in the cross-section ,
which is referred to as plane strain state or a flat plastic flow state. Therefore, it can be reduced to
two-dimensional plane strain problem in order to resolve orthogonal cutting. This simplified model
reduces the independent variable such as the blade angle, the cutting width, and so on, to simplify the
manufacturing state, which has been widely used in the theoretical and experimental work.
ABAQUS is a powerful finite element simulation software, which solve problems range from
relatively simple linear analysis to the many complex nonlinear problems. With further research, it
was found that the metal cutting process is a complex nonlinear process. For nonlinear problems
ABAQUS can get satisfactory results.

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 Advanced Materials Research Vols. 821-822 1411

Finite element simulation model

Geometric Model. In order to describe the shape of the tool and the work piece size in the cutting
simulation, geometric model need to be established. In order to adapt the characteristics of the finite
element analysis, the dimension and shape of the model may differ from the original of the geometry.
In this paper a two-dimensional cutting simulation is carried on, the tool and the work piece are
reduced to the planar state, the work piece is instead of rectangular, in view of the stiffness and
hardness are large relative to the work piece, the tool is assumed to be rigid. Both the tool and the
work piece has been modeled in ABAQUS.
Friction model . The friction model of finite element simulation for turning can be viewed as the
interaction between the chip and tool. In order to prevent deformation through the rigid body, when
the distance between the tool and the chip is zero, a calculation of interaction between the surfaces is
introduced. Normal stress of contact surfaces is related to the hardened chip, thus friction stress
calculated by the normal stress.
The contact surface of the tool and chip has two different zones: sliding friction and adhesion friction.
The friction stress of the former is proportional to the local normal stress while the latter one remains
constant.
µσ ( x); sliding friction zone
τ f ( x) =  n (1)
 τ int ; adhesion friction zone
Where, τ int is friction stress, which is the function of strain, strain rate, temperature contact surface
between tool and chip, µ is coefficient of friction, which is one constant determined.
Heat Transfer Model. Machining process produces a lot of heat, leading to rapid warming tool and
work piece. partial differential equations of heat conduction in the plane orthogonal cutting as
follows.

λ∂ +λ ∂
θ θ
2 2
 ∂θ ∂θ  •
− ρ C p  u x + uy +Q =0 (2)
∂x ∂y
2 2
 ∂x ∂y 
Where, λ is thermal conductivity; T is temperature; ρ is material density; C is specific heat capacity;
x, y is coordinates of Cartesian; u, v is the velocity component of movement heat in the direction of x
and y; Q is the heat generation rate per unit volume, obtained by the following formula
MWhW p
Q= (3)
ρ
Where, M is mechanical equivalent of heat; Wh is ratio when plastic deformation work is converted
into heat, assuming 90% of the plastic deformation work is converted into heat in here, Wh is taken as
90%; W p is plastic strain rate; ρ is material density.
The heat of friction is as follows between the tool rake face and chip and between the tool flank face
and the machined surface.
Q = Ft vγ (4)
Where, Ft is the friction of contact interface; vγ is relative sliding velocity of two contact surfaces.
The convection between free surface of the tool and the work piece and air is determined by the
following formula.
q c = h(Tw − T0 ) (5)
Where, h is coefficient of convective heat transfer; Tw is the surface temperature of work piece (or
tool); T0 is temperature of ambient air.
Chip separation model. Turning process , which is nonlinear, belongs plastic deformation in
Abaqus. In the cutting process based on the characteristics, namely dynamic and continuity, with the
movement of the tip, some grid cell may be extruded into the shape of the uneven distortion, so that
1412 Advances in Textile Engineering and Materials III

the calculation result will be the distortion. In order to ensure the normal operation of the cutting
process and calculation accuracy, grid must be re-divided and remove distortion unit during finite
element simulation. In this paper, the cell removal technique will be used in ABAQUS.
In the cutting process, taking into account the impact of the thermal-mechanical coupling on the
material properties, the Johnson-Cook model formula as following will be adopted.

[
σ = A+ B ε ( )]pl n

1 + C ln  (
 ε pl  
) ~
  1 − T m
 ε 0 
(6)

and,
0; T < Tt
~ 
T ≡ (T − Tt ) / (Tm − Tt ); Tt ≤ T ≤ Tm (7)
1; T > Tm

Where, A is quasi-static yield strength; B is coefficient of strain hardening; C is coefficient of strain
rate sensitivity; N is exponent of strain hardening; ε pl is rate of equivalent plastic strain; ε 0 is
reference strain rate; M is sensitivity index of strain rate; Tt is transition temperature; Tm is the
melting temperature of the work piece material.

Example
As example, workpiece material is 45 steel, tool material is Carbide YT15, specific performance
parameters see in Table 1. Work piece material hardening parameter was 0.12, the friction coefficient
of 0.28 is selected. The cutting process, the hardness of the tool is much higher than the hardness of
the work piece, so the tool is modeled as a rigid body while parts as a soft body, which is consistent
with the actual cutting process. Therefore, the workpiece using a large plastic strain plastic analysis
unit while the tool does not involve plastic deformation problem, and do not enter the stress-strain
curve.
Tab. 1 Material properties of workpiece and tool
material E(Gpa) μ ρ(kg/m3) σ s (MPa) σ b (MPa) δ s (%) ψ(%) ε max
Tool:YT15 209 0.272 7890 381 610 25 55 1.6
Workpiece:
213 0.290 7860 353 598 39 54 1.8
45#

The cutting simulation process is shown in Fig. 1 - Fig. 6.

Fig. 1 Contacting Fig. 2 Start cutting Fig. 3 Deformation

Fig. 4 Deformation Fig. 5 Chip separation Fig. 6 Stress distribution

 Advanced Materials Research Vols. 821-822 1413

Conclusion
Select cutting thickness in 1.0mm, by changing the value of rake angle (5,5, 15,20) to complete the
simulation., corresponding shear angle can be approximated measured in the mesh deformation maps
obtained from the calculation results, which illustrate that rake angle has the impact on the shear
angle. Simulation results show that the rake angle increases, the shear angle increases, as shown in Fig.
7. Tab. 2 shows the simulation results and experimental results while some errors found is small, and
changing trends of the value are correct. The results obtained by the simulation analysis about the
relationship between rake angle and shear angle have been given validation.

Fig.7 Comparative analysis of different rake angle

Tab. 2 Results compare of simulation and experimental
（
Rake angle degree ） -5 5 15 20

Shear angle simulation 43 52 52 58

（ degree） experiment 45 53 53 59

Acknowledgements
This work was financially supported by the National High-Tech Research and Development Program
of China (863 Program:2011AA04A102),Tianjin Municipal Science and technology key project
(10ZCKFSF01500), Research Development Fund of TUTE (KJY11-06) and Research Development
Fund of TUTE (KJ12-16).

References
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Advances in Textile Engineering and Materials III
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Finite Element Simulation of the Orthogonal Cutting Based on Abaqus

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