Finite element simulation of chip formation process in oblique cutting of aluminum alloy

Due to a need for a 3D 7inite element simulation model and having a high solution time, simulation of an oblique cutting process has some limitations and has been studied less. In this study, for solving these limitations, a 2.5D model was developed for analyzing the oblique cutting process and simulation of chip formation in this cutting process was established. Two deformable parts were modeled as tool and workpiece. Johnson-Cook material model and Johnson-Cook damage criteria were used. Then the effect of tool-rake angle, cutting edge inclination angle and cutting depth on aluminum-alloy chip morphologies were analyzed and it was seen that by decreasing the rake-angle, the chips became smaller. The increase in cutting edge inclination angle causes the chips become more conical and more continuous. There were segmented chips by increasing the cutting depth, as a result of increasing the undeformed chip thickness and amount of stress.