Abstract
This paper presents an FEA modeling strategy for predicting the cutting forces generated during linear wood machining. The objective is to determine both the forces and paths of cracks propagating in elastoplastic and anisotropic materials. The model combines a bilinear representation of the material strain-stress relation and the Hill yield function. The proposed procedure also integrates the displacement extrapolation method to evaluate the stress intensity factors. It establishes the cutting forces from the contact pressures between the tool and the chip. These pressures are determined using the penalty method. The validation phase compares the model predictions with average experimental forces and shows correspondence levels higher than 91% and 92% for low (0.085e10−3 m/s) and high (6.8 m/s) wood-feeding speeds, respectively. The developed model maintains a high precision degree over a large range of feeding-velocity. This study demonstrates that the resistive force between the chip and the tool surface is a function of both the rake angle φ and the coefficient of friction (COF). The friction force prompts a self-energizing effect, which increases the resistive force. On the other hand, larger φ amplitudes reduce this effect. Furthermore, the rake angle φ defines the crack propagation mode. Larger φ amplitudes favor the opening mode, whereas smaller values promote the shear mode. The COF amplitude also influences the surface quality, with larger COFs producing more profound cutting dimples. Thus, reducing the COF should result not only in lower cutting forces but also in a better surface quality of machined parts.
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Data availability
All input data considered during the simulations and necessary to reproduce the results are included in Tales 1 to 3, and Fig. 6. Therefore, no additional data is appended.
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Code availability
The results presented in the figures were obtained from a combination of the equations detailed in the text. The pseudo-code of Table 4 also describes the return-mapping algorithm adopted in this study to work hardening. Therefore, no additional code is appended.
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The support of NSERC (Natural Sciences and Engineering Research Council of Canada) is gratefully acknowledged.
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Aboussafy, C., Guilbault, R. Chip formation in machining of anisotropic plastic materials—a finite element modeling strategy applied to wood. Int J Adv Manuf Technol 114, 1471–1486 (2021). https://doi.org/10.1007/s00170-021-06950-6
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DOI: https://doi.org/10.1007/s00170-021-06950-6