Cutting Simulations Using a Commercially Available 2D/3D FEM Software for Forming

Chip formation simulations require either sophisticated material based element removal or deactivation routines, or a powerful remeshing procedure. Therefore the accuracy of all chip formation simulations significantly depends on the FEM-software as well as the material data. Over the course of the past years, a few select commercial programs became the pre-eminent choice for chip formation simulations. In this work, the software simufact.forming, which is not one of those few programs widely in use, has been employed for 2D and 3D chip formation simulations. Orthogonal cutting experiments with AISI4140 were conducted and subsequently modeled, including the cutting edge radius. The results were analyzed with regard to how well chip formation and the resulting process forces in 2D and 3D can be depicted.