Studies on the formation of discontinuous chips during rock cutting using an explicit finite element model

• Published in: International journal of advanced manufacturing technology Vol. 70; no. 1-4; pp. 635 - 648
• Main Authors: Menezes, Pradeep L., Lovell, Michael R., Avdeev, Ilya V., Lin, Jeen-Shang, Higgs, C. Fred
• Format: Journal Article
• Language: English
• Published: London Springer London 2014; Springer Nature B.V
• Subjects: Breakage; CAE) and Design; Chip breakers; Chip formation; Computer simulation; Computer-Aided Engineering (CAD; Constitutive models; Cutting force; Engineering; Finite element method; Fragmentation; Industrial and Production Engineering; Material properties; Mathematical analysis; Mathematical models; Mechanical Engineering; Media Management; Morphology; Numerical methods; Original Article; Separation; Simulation; Sliding; Tool steels; Finite element modeling; Rock cutting; Cutting forces; Chip formation
• ISSN: 0268-3768; 1433-3015
• DOI: 10.1007/s00170-013-5309-y

Predicting the fragmentation process during rock cutting poses significant technical challenges. In this respect, previous research related to rock cutting using various numerical methods was reviewed in detail. A method for simulating the fragmentation process during the mechanical cutting of rock was then introduced using the explicit finite element code LS-DYNA. In the numerical simulations, the base rock material properties were defined using a damage constitutive model. This model simulates the separation of rock chips from the base rock material and the subsequent breakage of the chips into multiple fragments. In the simulations, a rigid steel cutting tool was translated at various sliding velocities (1, 4, 10, 50, and 100 mm/s) against a stationary rock material. For a given sliding velocity, simulations were conducted for various cutting depths (1, 2, 3, and 4 mm). The variation of stresses and the amount of chip formation at different depths of cut and velocities were analyzed. The simulations indicated that the cutting forces and chip morphology were significantly influenced by sliding velocities and cutting depths. Overall, the results indicate that the explicit finite element method was a powerful tool for simulating rock cutting and the chip fragmentation processes, as it was able to predict chip separation behavior from the base rock at different depths of cut accurately.