Finite Element Modeling of Oblique Machining Using an Arbitrary Lagrangian–eulerian Formulation

A 3D finite element model (FEM) of the oblique chip formation process was proposed in Abaqus/Explicit™ (v6.5) using an Arbitrary Lagrangian Eulerian (ALE) formulation. The sensitivity of the obtained results to variations of tool geometry angles, tool-chip friction, and cutting conditions was analyzed. Experimental tests were carried out on AISI-4140 steel using uncoated cemented carbide tools under oblique cutting conditions for validation of the FEM results, and a good qualitative agreement between them was obtained. The analysis highlighted the need for a proper identification of the friction on the tool-chip interface for the accurate reproduction of the chip formation process by means of finite element modeling.