FINITE ELEMENT MODELING OF THE CUTTING PROCESS DURING MACHINING OF STRUCTURAL STEEL USING ANSYS WORKBENCH
The technique of modeling the cutting process when sharpening structural steel (steel 45) is presented. The 3D finite element simulations of machining are conducted using commercial code ANSYS Workbench. For the simulation of plastic deformation and failure of the materials, a Johnson-Cook model is used as constitutive equation to describe behavior of material during cutting process. This model takes into account the effects of the kinematic hardening and adiabatic heating of the deformable material. To model separation of chip from the workpiece, the Johnson–Cook (J–C) damage criterion is used. In the suggested model, the value of feed is taken into account as the width of the strip of the workpiece for modeling workpiece. As a result of modeling, the stress and strain fields for both the workpiece and the tool are presented, as well as the thermal field of the chip and the machined piece. The results are compared and evaluated with the experimental results; they are similar and do not contradict the traditional theory of the metal cutting. The proposed method of modeling allows to study the stress-strain state and thermal distributions of the cutting process, chip formation conditions and prediction of the quality of finished surface.