Computer simulation and optimization of metal cutting process for mild carbon steels

A computer simulation system is studied and set up for machining mild carbon steels based on a steady chip formation model. The modified updated Lagrangian finite element approach is utilized over the grid consisting of pair-triangles with the introduction of dilatational strain increment as an added freedom. Targets are built up for the optimum cutting parameters corresponding to the minimal cutting forces, minimal strains and the lowest temperature with certain productivity and tool life within ranges of the possible cutting parameters through the analyses of the cutting force field, stress field, strain rate field and temperature distribution, taking 0.2% carbon steel as an example, Experimental observations show that the simulation system works well and reliably and gives better parameters for the cutting processes.