On the separation criteria in the simulation of orthogonal metal cutting using the finite element method

This paper aims to gain an understanding of the reliability of the existing separation criteria for orthogonal metal cutting. To focus on their physical inherence, a simple finite element model under plane-strain deformation was used to investigate the mechanics of cutting from the incipient stage. The workpiece materials studied were elastic–perfectly plastic and elastic–plastic with work hardening. The chip separation criterion of failure stress was used as a default and based on this the thresholds and reliability of different criteria were examined. The study showed that none of the existing criteria is universal. A more comprehensive criterion needs to be established to provide consistent and reliable FEM simulation. © 1999 Elsevier Science S.A. All rights reserved.