Modelling and simulation of high-speed machining

A Lagrangian finite element model of orthogonal high-speed machining is developed. Continuous remeshing and adaptive meshing are the principal tools which we employ for sidestepping the difficulties associated with deformation-induced element distortion, and for resolving fine-scale features in the solution. The model accounts for dynamic effects, heat conduction, mesh-on-mesh contact with friction, and full thermo-mechanical coupling. In addition, a fracture model has been implemented which allows for arbitrary crack initiation and propagation in the regime of shear localized chips. The model correctly exhibits the observed transition from continuous to segmented chips with increasing tool speed.