Finite element analysis for chip formation in high speed turning operations by arbitrary Lagrangian Eulerian method

A two-dimensional finite element (FE) model for the high speed turning operations when orthogonally machining AISI H13 tool steel at 49HRC using polycrystalline cubic boron nitride (PCBN) is described. An arbitrary Lagrangian Eulerian (ALE) method has been adopted which does not need any chip separation criteria as opposed to the traditional Lagrangian approach. Through FE simulations temperature and stress distribution are presented that could be helpful in predicting tool life and improving process parameters. The results show that high temperatures are generated along the tool rake face as compared to the shear zone temperatures due to high thermal conductivity of PCBN tools.