On the finite element modeling best practices for the metal cutting simulations

Finite element analysis is a widely used method to analyze solid mechanics problems. This method is also popular on metal cutting simulations as cutting process results and characteristics can be obtained in great detail. Despite the modeling and results screening capabilities of this technique, the fidelity of the method is highly dependent to the modeling approach and inputs. In case of metal cutting simulations, modeling may become more challenging due to the excessive work material deformation at high strain rate levels and coupled thermal effects. Different techniques are proposed in literature studies in order to overcome modeling difficulties and improve simulation accuracy but those are mostly proposed for specific problems. The aim of this study is to establish finite element modeling best practices for the metal cutting process which are intended to be generic approaches for different type of problems. For this purpose, detailed evaluation of the tool – work material interaction is performed by considering process geometry and deformation characteristics. FE simulation results are compared with experimental results in order to determine FE modeling best practices in an efficient manner.