Finite element formulation effect in three-dimensional modeling of a chip formation during machining

This work aims to analyze the finite element (FE) formulation effect on three-dimensional (3D) simulation of an orthogonal cutting test. Johnson-Cook visco-plastic-damage model for the machined material and rigid with thermal behaviour for the tool are assumed. At the chip/tool contact zone, the Coulomb friction model is adopted. Also, the thermal aspects are considered by taking into account the heat flux generated by inelastic strain and contact with friction between the workpiece and the cutting tool. In order to analyse the finite element formulation effect, the workpiece is meshed with a 3D continuum elements of ABAQUS/Explicit FE library, a coupled displacement-temperature 8 nodes solid elements, either with full integration (C3D8T) or with reduced integration and hourglass control (C3D8RT). The performed analysis shows a direct influence of the FE formulation, especially the hourglass control treatment on the obtained results. Chip curvature, cutting forces, normal and shear friction stresses and temperature distribution in the workpiece and tool are clearly depending on the FE type. So, it is important carefully conduct the FE analysis of cutting processes, in order to obtain accurate results.