Finite element modelling and characterisation of chip curl in nose turning process Online publication date: Tue, 02-May-2017
by Ashwin Devotta; Tomas Beno; Ronnie Löf
International Journal of Machining and Machinability of Materials (IJMMM), Vol. 19, No. 3, 2017
Abstract: Finite element (FE) modelling of machining provide valuable insights into its deformation mechanics. Evaluating an FE model predicted chip morphology requires characterisation of chip shape, chip curl and chip flow angles. In this study, a chip morphology characterisation methodology is developed using computed tomography (CT), high-speed imaging and Kharkevich model equations enabling evaluation of FE model's chip morphology prediction accuracy. Chip formation process in nose turning of AISI 1045 steel is simulated using a 3D FE model for varying feed rate and depth of cut and evaluated against experimental investigations using the employed methodology. The study shows that the methodology is able to characterise chip morphology in nose turning process accurately and enables evaluation of FE model's chip morphology prediction accuracy. This can enable the finite element model to be deployed in cutting tool design for chip breaker geometry design.
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