Analysis of orthogonal metal cutting processes

The orthogonal metal cutting process for a controlled contact tool is simulated using a limit analysis theorem. The basic principles are stated in the form of a primal optimization problem with an objective function subjected to constraints of the equilibrium equation, its static boundary conditions and a constitutive inequality. An Eulerian reference co‐ordinate is used to describe the steady state motion of the workpiece relative to the tool. Based on a duality theorem, a dual functional bounds the objective functional of the primal problem from above by a sharp inequality. The dual formulation seeks the least upper bound and thus recovers the maximum of the primal functional theoretically. A finite element approximation of the continuous variables in the dual problem reduces it to a convex programming. Since the original dual problem admits discontinuous solutions in the form of bounded variation functions, care must be taken in the finite element approximation to account for such a possibility. This is accomplished by a combined smoothing and successive approximation algorithm. Convergence is robust from any initial iterate. Results are obtained for a wide range of control parameters including cutting depth, rake angle, rake length and friction. The converged solutions provide information on cutting force, chip thickness, chip stream angle and shear angle which agree well both in values and trend with the published data. But the available data represent only a small subset in the range of parameters exhaustively investigated in this paper.