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Procedia CIRP 58 (2017) 73 – 78

16th CIRP Conference on Modelling of Machining Operations

Cutting simulations using a commercially available 2D/3D FEM software

for forming.
Eric Segebadea,*, Michael Gerstenmeyera, Frederik Zangera, Volker Schulzea
a
wbk – Institute of Production Science, Karlsruhe Institute of Technology (KIT), Kaiserstr. 12, 76131 Karlsruhe, Germany
* Corresponding author. Tel.: +49-721-608-45906 ; fax: +49-751-608-45004. E-mail address: [email protected]

Abstract

Chip formation simulations require either sophisticated material based element removal or deactivation routines, or a powerful remeshing
procedure. Therefore the accuracy of all chip formation simulations significantly depends on the FEM-software as well as the material data.
Over the course of the past years, a few select commercial programs became the pre-eminent choice for chip formation simulations. In this
work, the software simufact.forming, which is not one of those few programs widely in use, has been employed for 2D and 3D chip formation
simulations. Orthogonal cutting experiments with AISI4140 were conducted and subsequently modeled, including the cutting edge radius. The
results were analyzed with regard to how well chip formation and the resulting process forces in 2D and 3D can be depicted.
© 2017 The Authors. Published by Elsevier B.V.
© 2017 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license
Peer-review under responsibility of the scientific committee of The 16th CIRP Conference on Modelling of Machining Operations, in the
(http://creativecommons.org/licenses/by-nc-nd/4.0/).
person of the
Peer-review Conference
under Chairs
responsibility of the Prof. J.C.
scientifi Outeiro of
c committee andTheProf.
16th G. Poulachon.
CIRP Conference on Modelling of Machining Operations

Keywords: Finite element methid (FEM); Cutting, Chip formation

1. Introduction such as element deletion, node separation, continuous or

discontinuous re-meshing, or by a combination of these. As
The modeling and simulation of cutting operations is shown in [9], the friction models and coefficients chosen
steadily gaining momentum in terms of its utility for predicting profoundly influence the quality of simulations (regardless of
macroscopic part performance. Various models from various software) and remain a critical factor for depicting cutting in
scientific institutes and companies can already predict the simulations. Many of these methods have been evaluated by
cutting forces, temperatures, microstructural and phase [10], who conclude that the simulation predictions vary widely
changes, residual stresses, tool wear, tool life, and even chip depending on the software package, the modeling strategy, and
type for machining operations [1-6]. (using the same software) the user. An even more detailed
Several software applications are most widely used for benchmark of simulation software for cutting processes is
FEM- simulations of cutting operations (alphabetical order): planned over the next few years within the scope of a CIRP
x Abaqus collaborative work.
x Advantedge Future refinements in the FEM-simulations of cutting
x Ansys/LS-Dyna operations will focus on the incorporation of: physics-based
x Deform material models (e.g., those considering microstructure),
x Forge friction models obtained with cutting-relevant experimental
There are also some non-commercial custom programs and data, thermal conductivity models, workpiece state data that
program modifications in use. accounts for upstream processing, cutting edge
In addition to FEM-simulations, meshless techniques [7] and microgeometries, tool roughness, and wear data. Improvements
smooth particle hydrodynamics (SPH) [8] can also be used to in 3D simulations and computation speed – particularly when
depict the cutting processes of various materials. Chip simulating complete parts – are also areas of interest.
formation can be simulated within FEM via different strategies,

2212-8271 © 2017 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license
(http://creativecommons.org/licenses/by-nc-nd/4.0/).
Peer-review under responsibility of the scientific committee of The 16th CIRP Conference on Modelling of Machining Operations
doi:10.1016/j.procir.2017.03.195
74 Eric Segebade et al. / Procedia CIRP 58 (2017) 73 – 78

Even though advanced cutting simulations usually focus on ܵ is the arithmetic mean of Sγ and Sα. Table 2 shows the
the resulting surface integrity details, such as residual stresses combinations of tool microgeometry and experiment. It is
and microstructural changes, the first step in model validation notable, that none of the cutting edges features a Κ equal to or
is to predict the cutting forces for a range of process parameters. smaller than 1. All edges exhibit a Sγ that is at least 10% longer
Without realistic cutting forces, the resulting predicted surface than the respective Sα.
integrity can hardly be considered physically correct – barring
the possibility of fitting prediction models to experimental data Table 2. Cutting edge radii of the WKM P8TN 6028833
using incorrectly calculated forces (and, in turn, incorrectly cutting velocity
uncut chip mean cutting form-
calculated stress, deformation and possibly temperature fields). thickness edge radius factor
vc in m/min
h in µm ܵ in µm Κ
The asymmetry of the cutting edge should also be considered,
since experience shows that edge asymmetry not only 80 25 35.0 1.8
influences process forces [11] but also the resulting surface 80 50 35.0 1.1
integrity of parts [12]. According to the literature, a change in 80 100 41.0 1.2
the edge segment length at the flank face Sα will likely impact 100 25 44.0 1.3
the process forces more severely than a change in the edge
100 50 38.5 1.6
segment length of the rake face Sγ [13].
100 100 39.5 1.5
In this work, a 2D and 3D orthogonal cutting model is set up
using the commercial FEM-software simufact.forming. The 150 25 33.5 1.2
software specializes in forming and joining operations and has 150 50 44.0 1.4
not previously been used for chip formation simulation. 150 100 39.0 1.7
Following a brief analysis of the system’s sensitivity to cutting
edge asymmetry, an investigation of friction parameters is
3. FE-Simulations
conducted. Finally, the model is tested against experimental
cutting force data obtained for different process parameters
3.1. 2D-FE-Model
with AISI 4140 considering the real cutting edge
microgeometries.
2D-FE-simulations were set up with two different accuracy
settings henceforth referred to as “basic” and “normal”. The
2. Experiments
basic setup features approximately three times bigger elements
than the normal setup. The basic setup was used for the
2.1. Experimental setup
comprehensive friction coefficient study. The normal setup as
shown in Fig. 1 was compared with the experimental data as
Orthogonal cutting experiments with AISI 4140 QT were
well as the sensitivity analysis regarding cutting edge
carried out on a Karl Klink vertical broaching machine.
asymmetry. In all cases the length of cut was set as 1 mm. The
Workpieces with dimensions of 80x4x20 mm with the depth of
workpiece was modeled with a length of 4 mm and a thickness
cut applied to the height of 20 mm were used. While the
of 1 mm.
workpiece is moved vertically, the tool is fixed on a three
The mesh type “Quadtree” in plane strain condition with
component dynamometer Type Z 3393 by Kistler. A rake angle
continuous remeshing depending on refinement boxes was
of -7° was used for all experiments. All experiments were
used. The number of elements varied with uncut chip thickness
repeated three times. Additionally a new characterized cutting
with the highest number of elements necessary for 100 µm of
edge was used for each set of parameters. The three sets of
uncut chip thickness. In the example shown in Fig. 1 (uncut
process parameters are listed in Table 1.
chip thickness of 100 µm) the number of elements increased
Table 1. Orthogonal cutting experiments with AISI 4140 QT with length of cut from 15000 to up to 85000 elements.
set cutting velocity vc
uncut chip thickness h in µm
no. in m/min
1 80 25 50 100 Tool
1200 elements, rigid with heat conduction
2 100 25 50 100
3 150 25 50 100 Mesh refinement boxes
48 µm base size
1.5 µm minimum size

2.2. Cutting tools and cutting edge characterization

Uncoated Walter Tools cutting inserts type WKM P8TN

Workpiece
6028833 with a cutting wedge angle of 90° and thus a flank up to 15000 elements (start)
angle of 7°. The inserts were shipped with a nominal cutting up to 85000 elements (1 mm cut)

edge radius of 40 ± 10 µm. Each edge was analyzed using a Holder

(vc applied via glued contact)
confocal light microscope of the NanoFocus AG and
subsequently characterized by the form-factor method [14].
The form-factor Κ is the ratio of edge segment lengths Sγ at the
rake face and Sα at the flank face. The mean size of the radius Fig. 1. 2D-cutting model (normal accuracy)
 Eric Segebade et al. / Procedia CIRP 58 (2017) 73 – 78 75

3.2. 3D-FE-Model as well as increasing strain rate increases the thermal

component ߪ ‫ כ‬ሺܶǡ ߝሶሻ. Above a set temperature (T0) the thermal
For 3D-FE-simulations both hexahedral and tetrahedral component ceases to influence the flow stress. T0 is defined as
οீబ
meshes were used. In case of the hexahedral mesh the elements ܶ଴ ൌ  ഄሶ
(2)
are distributed between the base element edge length of 120 µm ௞ಳ ୪୬ቆ బሶ ቇ
ഄ೛
and the minimal edge length of 7.5 µm. The initial number of with the free activation enthalpy ο‫ܩ‬଴ and the Boltzmann
elements of 66000 increases with length of cut up to 254000 constant kB.
elements at 1.0 mm length of cut. The tetrahedral mesh features Long range dislocation obstacles are considered through the
a base element edge length of 100 µm and a minimal edge athermal component ߪீ . It is mostly independent of the
length of 5 µm. Concurrent with the 2D-FE-simulations the temperature T and considers the shear modulus G. With the
number of elements necessarily increased with uncut chip term ‰ሺǡ–”ሻ high temperature softening is considered
thickness. Due to a sharp increase in element count and failed depending on the transition temperature Ttr. It is defined as 1
remeshing no refinement boxes were used for the tetrahedral for ൑–”. For ൐–”. ‰ሺǡ–”ሻ is defined as
mesh. The setup of the 3D-hex simulation is depicted in Fig. 2. 9
§ § T  T (H ) ·[ ·
The workpiece was modeled with 1 mm in depth to the g (T , Ttr ) ¨1  ¨ tr p
¸ ¸ (3)
dimensions of the 2D-setup. Using a symmetry plane half of the ¨ ¨ T  T (H ) ¸ ¸
© © m p ¹
¹
experimental setup is depicted. This measure to reduce
with
computational time is not suspected to reduce accuracy more
§ H p ·
than a significantly coarser mesh, which would have been Ttr (H p ) -0  '- ˜ ln ¨¨1  ¸¸ (4)
necessary otherwise. All simulations were computed without © Hn ¹
parallelization on a desktop PC. and the material constants ߴ଴ ǡ οߴǡ Ɍǡ ɑ and the melting
temperature Tm. The model has already been validated for
cutting simulations in numerous works using Abaqus (e.g.
Tool [15]). The workpiece was defined as elasto-plastic.
64000 elements, rigid with heat conduction
The tool is modeled as rigid with heat conduction (transport
coefficient at the interface: 108 Wm-2K-1). Both bodies initial
temperature is set to 293°K. A heat transfer coefficient to the
Mesh refinement boxes environment of 50 Wm-²K-1 and temperature dependent
120 µm base size emissivity from 0.02 at 293.15°K to 0.55 at 1273.15°K is
7.5 µm minimum size
defined.
The tool is fixed in space while the workpiece is moved
Holder through a glued contact with a moving rigid “holder”. The
(vc applied via glued contact)
software offers forging press kinematics (which are mostly not
Workpiece
66000 elements (start) relevant for cutting), tabular data or subroutine to realize tool-
250000 elements (1 mm cut) movements. For this study a constant velocity in one direction
was modeled with a hydraulic press.
Fig. 2. 3D-cutting model (hexahedral mesh) The software allows the definition of temperature dependent
coulomb friction, combined coulomb-shear friction and
subroutine implementation of friction laws. In this study a
3.3. Material model and boundary conditions temperature independent combined coulomb-shear friction
model was used. The friction coefficients were varied as per
The software works with numerous fortran-based Table 2. Parameter range was chosen according to past
subroutines of different functionalities. For this study the experience [15], which suggests a value of µ = 0.35 for
subroutine “user_fstress” was used to implement a physics coulomb friction for AISI4140 and uncoated cutting tools. The
based material model according to [16-18] for the workpiece. study was conducted using the basic accuracy and the cutting
The model suggests the flow stress ߪ to be composed of a edges and process parameters as listed in Table 2. A total of 81
thermal component (ߪ ‫ כ‬ሺܶǡ ߝሶሻ) and an athermal component (ߪீ ). simulations were run for the friction study.
Dependency on temperature ܶ and strain rate ߝሶ is considered as
shown in Eq. 1. Table 3. Full-factorial friction coefficient study
m
§ § T ·n · coulomb factor µ shear factor m
V V 0* ˜ ¨1  ¨¨ ¸¸ ¸
¨ © T0 ¹ ¸ 0.25 0.5
© 
 ¹
 (1)
V* 0.35 0.7
§ § § T1 ˜ H p · · ·¸ G (T ) 0.45 0.9
¨
 
 ¨ V G 0  V 1  T1 ˜ H p ˜ ¨1  exp ¨ 
¨ ¨
¸¸ ˜
T 0 ¸¹ ¸¹ ¸ G (0 K )
˜ g T , Ttr 
©  © ©

¹  3.4. Cutting edge microgeometries
VG
‫כ‬
The thermal component ߪ ሺܶǡ ߝሶሻ considers short range In order to study the sensitivity regarding cutting edge
dislocation obstacles with regard to temperature T, strain rate ߝሶ asymmetry, simple asymmetric cutting edges were created. The
and the material constants n and m. Lowering the temperature
76 Eric Segebade et al. / Procedia CIRP 58 (2017) 73 – 78

edges feature a Κ of 2 and 0.5 with a ܵ of 45 µm. Additionally Table 4. Modeled coefficients of friction rating regarding process forces
two symmetrical cutting edges with rβ = 30 µm and 60 µm coulomb coefficient µ shear coefficient m rating
were used. The simulations were conducted in 2D, with low 0.35 0.7 1
coulomb friction (µ = 0.1). The low, constant friction
0.35 0.5 2
coefficient ensures reduced influence of the contact length on
0.45 0.5 3
the cutting forces. Instead, the microgeometry-dependent
ploughing influences the forces most strongly. With this effect 0.35 0.9 4
predicted correctly, the simulation will be suitable for future 0.25 0.5 5
works considering surface integrity details dependent on 0.25 0.9 6
cutting edge microgeometry. 0.25 0.7 7
For the force comparison with the experiments, all measured
0.45 0.7 8
cutting edges as listed in Table 2 were recreated and used for
0.45 0.9 9
the corresponding process parameters in 2D and 3D.

4. Results and discussion 4.3. Force comparison simulations - experiments

4.1. Sensitivity to cutting edge asymmetry Before conducting the simulation study with the normal
setup, the influence of element size on cutting forces was
In Fig. 3 the process forces of the four different cutting edges analyzed. The simulation modeled with 25 µm chip thickness
analyzed in this study are shown. As literature suggests, and cutting speed of 150 m/min was run with different element
asymmetric cutting edges result in higher forces in general, with sizes up to a length of cut of 1 mm. Simulations with
a more pronounced influence of change in the flank face edge significantly different element sizes (from 12 to 0.75 µm)
segment Sα due to ploughing. It can be deduced, that the yielded comparable cutting forces, as shown in Fig 4. The
simulation results show sensitivity of the correct tendency for element size of the normal setup was considered to be sufficient
cutting edge microgeometries regarding the process forces. and time efficient.
All further results shown in this chapter were modeled using
…—––‹‰ˆ‘”…‡ ’ƒ••‹˜‡ˆ‘”…‡
the friction coefficients of µ = 0.35 and m = 0.7 and normal
ͳ͵ͲͲ
accuracy. Steady state was reached after approximately 0.4 mm
ͳʹͲͲ length of cut. Fig. 5 to 7 show the results in comparison with
the experiments. The 3D-simulations with a tetrahedral mesh
ͳͳͲͲ
are farthest off in all cases. Most forces are severely
ͳͲͲͲ underestimated using this mesh type. It is therefore not a good
choice for setting up cutting simulations with this software.
ͻͲͲ
Apart from the bad results, the tetrahedral mesh also requires a
ͺͲͲ high number of restarts due to instabilities.
2D-simulations and 3D-simulations using the hexahedral
͹ͲͲ mesh slightly overestimate the cutting force for small uncut
͸ͲͲ chip thickness. At higher uncut chip thickness, the cutting force
is predicted accurately. Contrary to this trend, the passive force
ͷͲͲ is accurate for small uncut chip thickness, but underestimated
ͶͲͲ for high uncut chip thickness at low speed. The reason for this
”Ⱦൌ͵Ͳρ”Ⱦൌ͸Ͳρ ȥൌʹǤͲ ȥൌͲǤͷ could be an underestimation of the frictional force applied to
(Sγ=60 μm, Sα=30 μm and Sγ=30 μm, Sα=60 μm)
the rake face, which should scale with uncut chip thickness.
Fig. 3. 2D-simulation of cutting and passive forces with symmetrical and
This effect is enhanced by low temperatures at this interface.

4.2. Friction coefficient study ͷͲͲ

‘’—–ƒ–‹‘–‹‡ሺͳ…‘”‡ሻ‹‹

͹Ǥͷ
The coefficients of the full-factorial study were rated by the Ͷ͹ͷ
—––‹‰ˆ‘”…‡‹

sum of error squares across the whole field considering both, ͳ͸

cutting and passive force. The rating is shown in Table 4. The ͶͷͲ
lowest error was observed using the parameters µ = 0.35 and
m = 0.7. The difference in accuracy is small for the first three Ͷ͹
parameter sets, but increases down the list. The parameters Ͷʹͷ ʹ͹ͷ
found correspond well to what can be found in literature. Better ʹ͹ͲͲ
results might be obtained with an additional study near the three ͶͲͲ
sets rated best. In the end, a temperature, relative velocity and ͷͲͲ ͷͷͲ ͸ͲͲ ͸ͷͲ ͹ͲͲ ͹ͷͲ
pressure dependent model should result in higher accuracy. ‡‰–Š‘ˆ…—–‹ρ
With 8 simulations running at the same time on one desktop ‹‹—‡†‰‡ Ž‡‰–Š
PC, the time required for computation was roughly 30 hours. ͳʹρ ͸ρ ͵ρ ͳǤͷρ ͲǤ͹ͷρ
Fig. 4. Influence of element size on simulated cutting force and computation
time by minimum edge length
 Eric Segebade et al. / Procedia CIRP 58 (2017) 73 – 78 77

š’‡”‹‡– ʹ‹—Žƒ–‹‘
͵‹—Žƒ–‹‘‡š ͵‹—Žƒ–‹‘‡– ˜…ൌͺͲȀ‹ Š…ൌʹͷρ ˜…ൌͳͷͲȀ‹
ͳͶͲͲ ˜… ൌͳͷͲȀ‹
ͳʹͲͲ
…—––‹‰ˆ‘”…‡ ’ƒ••‹˜‡ˆ‘”…‡
ˆ‘”…‡‹

ͳͲͲͲ
ͺͲͲ
͸ͲͲ
ͶͲͲ
ʹͲͲ Fig. 8. Simulated process temperatures at 80 and 150 m/min for uncut chip
ʹͷ ͷͲ ͳͲͲ ʹͷ ͷͲ ͳͲͲ thicknesses of 25 µm
—…—–…Š‹’–Š‹…‡••‹ρ
Fig. 5. Experimental and simulated process forces at 150 m/min for uncut ˜…ൌͺͲȀ‹ Š…ൌͳͲͲρ ˜…ൌͳͷͲȀ‹
chip thicknesses of 25 to 100 µm
š’‡”‹‡– ʹ‹—Žƒ–‹‘
͵‹—Žƒ–‹‘‡š ͵‹—Žƒ–‹‘‡–
ͳͶͲͲ ˜… ൌͳͲͲȀ‹
ͳʹͲͲ …—––‹‰ˆ‘”…‡ ’ƒ••‹˜‡ˆ‘”…‡
ˆ‘”…‡‹

ͳͲͲͲ
ͺͲͲ
͸ͲͲ Fig. 9. Simulated process temperatures at 80 and 150 m/min for uncut chip
ͶͲͲ thicknesses of 100 µm
˜…ͺͲȀ‹ ˜…ͳͲͲȀ‹ ˜…ͳͷͲȀ‹
ʹͲͲ ͳͷͲͲ
ʹͷ ͷͲ ͳͲͲ ʹͷ ͷͲ ͳͲͲ
—…—–…Š‹’–Š‹…‡••‹ρ
Fig. 6. Experimental and simulated process forces at 100 m/min for uncut ʹǦ•‹—Žƒ–‹‘…—––‹‰ˆ‘”…‡ …‹
chip thicknesses of 25 to 100 µm
š’‡”‹‡– ʹ‹—Žƒ–‹‘
͵‹—Žƒ–‹‘‡š ͵‹—Žƒ–‹‘‡–
ͳͶͲͲ ˜… ൌͺͲȀ‹
ͳʹͲͲ …—––‹‰ˆ‘”…‡ ’ƒ••‹˜‡ˆ‘”…‡
ˆ‘”…‡‹

ͳͲͲͲ
ͺͲͲ
͸ͲͲ
ͶͲͲ
ʹͲͲ ͳͷͲ
ʹͷ ͷͲ ͳͲͲ ʹͷ ͷͲ ͳͲͲ
ͳͷͲ ͳͷͲͲ
—…—–…Š‹’–Š‹…‡••‹ρ
‡š’‡”‹‡–ƒŽŽ›‡ƒ•—”‡†…—––‹‰ˆ‘”…‡ …‹
Fig. 7. Experimental and simulated process forces at 80 m/min for uncut chip
thicknesses of 25 to 100 µm Fig. 10. Cutting forces of the 2D-simulations vs. experimental cutting forces

On the one hand, a higher interface temperature should lead ˜…ͺͲȀ‹ ˜…ͳͲͲȀ‹ ˜…ͳͷͲȀ‹
ͳͷͲͲ
to higher friction coefficients and thus higher frictional forces.
On the other hand, higher speeds should decrease frictional
ʹǦ•‹—Žƒ–‹‘’ƒ••‹˜‡ˆ‘”…‡ ’‹

forces [15]. As can be seen in Fig. 8 and 9, the simulations

show the tendency of rising interface temperature with both,
uncut chip thickness and cutting speed. The temperature and
speed independent friction model and its coefficients can
therefore not depict all circumstances present at the tool chip
interface across the simulations. Validation of the model
regarding the predicted temperatures remains subject of future
work including measurement of temperatures during
experiments. Still, the temperatures as shown in Fig. 8 and 9
seem reasonable for dry machining.
In Fig. 10 (cutting force) and Fig. 11 (passive force), the
results of the 2D-simulations were plotted on the experimental ͳͷͲ
data considering a deviation of 20%. It is apparent, that all of ͳͷͲ ͳͷͲͲ
the forces are predicted with a deviation of slightly below 20%, ‡š’‡”‹‡–ƒŽŽ›‡ƒ•—”‡†’ƒ••‹˜‡ˆ‘”…‡ ’‹
if the experimental data variance is considered. Fig. 11. Passive forces of the 2D-simulations vs. experimental passive forces
78 Eric Segebade et al. / Procedia CIRP 58 (2017) 73 – 78

5. Conclusion and outlook Acknowledgements

In this work, a commercial FEM-software for forming The authors would like to thank Juo Son, who contributed
operations was used for 2D and 3D (orthogonal) chip formation to the programming of the material subroutine during his
simulation. The software has not previously been used for this master thesis.
kind of simulation.
To reflect material behavior, a constitutive material model References
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