Visual Numerical Simulation of Turning Machining Chip Formation

To simulate the formation of the turning machining chip in a virtual environment, the curling reasons, breaking conditions and generating thickness of chip are discussed, and numerical simulation models are built according to formation mechanism of chip. The 3-D solid models of chip are given according to classification criterion of chip, furthermore, the effect of machining parameters on shape dimension and types of chip are analyzed. On the basis of above researches, the real-time simulation system of chip generating, curling and breaking is developed by integrating curling radius, breaking condition and thickness of chip etc. into simulation models. The method of FEM modeling in 3-D curled chip and the condition of chip breaking are introduced, and a type chip is modeled and analyzed through FEM. Comparisons made between the experiment analyses and finite element models show good correlation, and the forecast ability of FEM simulation in chip formation was proved. Finally, above methods are verified by FEM. The system can gain corresponding chip types and dimensions, and real-time simulating chip generating, curling and breaking according to different parameters input.