Simulation and Development of Advanced Cutting Tools via Dynamic Finite Element Analysis

This paper presents a new method of predicting 3D chip formation for industrial cutting tools using FEM simulations. Unique features of this approach include use of calibrated material properties and verification of the model using practical experiments. An alternative approach to physical testing for finding material properties at high strain rates and temperatures using experimental data is also demonstrated here. Material data is used to calibrate the software. This approach has been used in process optimization as well as to develop advanced cutting tools.