An Investigation of the Chip Segmentation Process Using Finite Elements

Abstract

A finite element model of a two-dimensional orthogonal metal cutting process is used to simulate the formation of segmented chips. The deformation of the chip during segmentation is studied and the distribution of deformation energy in chip and shear band is analyzed. It is shown that the plastic deformation both in the shear band and the segment contribute significantly to the cutting force. A variation of the thermal conductivity strongly affects the segmentation and indicates that segmentation is energetically favorable.