Three Dimensional Numerical Modeling of Face Turning Using the Coupled-Eulerian-Lagrangian Formulation

Modeling the cutting process by means of Finite Element (FE) simulations found wide acceptance in the scientific community. Most of these studies focused on the simulation of the orthogonal cutting process. However, the orthogonal cutting process has only limited application in the metal cutting industry. Simulations of three-dimensional processes, such as face turning, are characterized by high computational times. In this study, a FE-model of face turning is presented, wherefore the Coupled-Eulerian-Lagrangian formulation is used. The computational time of the simulations was reduced to approximately 6 h, which allowed a time-efficient use of FE-simulations to analyze the face turning process. The results of the simulations are evaluated by comparing them with corresponding experimental cutting tests. The comparison of the results revealed a good agreement between the simulated and the experimental cutting forces, whereas the simulated passive and feed force deviated to a larger extend from the experimental counterparts.