Introduction

                     Metal cutting, commonly called machining, is the removal of unwanted metal from a work piece in the form of chips so as to obtain a finished product of desired size, shape and surface finish.
The economics of metal machining can no longer be determined solely by production cost. The true economics must involve a consideration of the behaviour of a machined component in service, especially if surface sensitive properties such as fatigue, creep and stress corrosion cracking become important.
Thus, knowledge of the nature and quality of the surfaces of the machined components produced under various conditions is of considerable industrial importance.
In general case of cutting known as oblique cutting, the cutting edge of the tool and the cutting motion are not perpendiculars to each other. The special case whine the cutting edge is perpendicular to the direction of relative work tool motion is known as Orthogonal Cutting.

                   The finite element method will be used to model chip formation in orthogonal metal cutting. Emphasis will be given on analysis the effect of important factors on the cutting process. Finite element simulation of orthogonal cutting will be performed for different coefficients of friction and unworn or worn tools having a strongly adherent build-up edge to investigate the significance of deformation of the workpiece material on the cutting process. Elastic-perfectly plastic and elastic-plastic with isotropic strain hardening and strain rate sensitivity constitutive laws is going to be used in the analysis.
The aim of the study is to develop a finite element model, which accounts for most essential features observed in the model such as, strain hardening and strain rate sensitivity effect, interfacial friction, wear geometry of the tool and BUE (built-up edge). The effect of each of these parameters on cutting is going to be examined in light of the resulting deformation configuration of the workpiece medium, the stress-strain fields, the distribution of the interfacial stresses, and the variation of cutting forces, shear angle, chip thickness, and contact length, under the various cutting conditions simulations.
 
 

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