A critical overview of machining simulations in ABAQUS.

Abstract: Metal cutting is one of the most commonly occurring manufacturing processes in the industry and major effort is made to improve its processes. Cutting tools are expensive and have a life length measured in minutes, why predictions of tool wear are of great interest. Finite Element (FE) simulations have a central role in the development of tools and cutting processes, but performing simulations of metal cutting is not easy. The method chosen for the chip formation has a large impact on the result of the simulations. The scope of this work includes a survey on important parameters and different possibilities to form a chip in simulations of metal cutting in ABAQUS/Explicit. Particular emphases are placed the on  prediction of flank wear and how the hardening implemented in the material model effects this. The approach has been to start with a literature study and thereafter make simulations in ABAQUS/Explicit. FE simulations, of cutting, with different damage criteria and simulations with SPH (Smooth Particle Hydrodynamics)- method are presented. None of the possibilities to form a chip in ABAQUS/Explicit, as implemented today, seems to be sufficient for simulations of cutting to predict flank wear. The SPH-method will be a good alternative for simulations of metal cutting in ABAQUS/Explicit if temperature dependency is implemented. The material model in general, the type of hardening in specific, has an impact on the chip-form and the stress state in the chip and workpiece. And thereby effects the flank wear.