Chip Formation in Orthogonal Cutting

This paper is the result of a cooperation between the Institute for Production Engineering and Machine Tools (IFW), University of Hannover, Germany and the Department of Mechanical Engineering of the University of Brescia, Italy. The aim of the work is to validate the reliability of a Finite Element code in simulating orthogonal cutting operations. Experimental tests on orthogonal cutting have been realized at the IFW while FE simulations were carried out at the University of Brescia. The collected data have been used to define the input variables of the FE code and to analyze the FE outputs. The experimental data in terms of cutting forces and chip morphology have been compared with the FEM results. The good agreement between experiments and simulations shows that FEM can be a valid help in tool designing and in identifying the process parameters also for the study of cutting operations.