Chip formation modeling using traction-separation cohesive model

Abstract

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Numerical models of machining require criterion (maximum equivalent strain, maximum shear stress, or damage fracture models) to separate the chip from the workpiece. In this work, we propose to use cohesive element methodology to remove the chip from the machined material. The paper is focused on the determination of cohesive parameters for the numerical modeling of chip formation process applied to titanium alloy. A numerical study is presented to calibrate the number of elements necessary in the cohesive zone thickness, the values of traction-separation energy, and the cohesive interaction parameter used in the 2D cutting model; the calibration is realized comparing numerical results of cutting forces and chip morphology with experimental analysis.