An efficient implementation of boundary conditions in an ALE model for orthogonal cutting

Prediction of machining-induced residual stresses is an interesting objective in the field of modelling manufacturing processes. Although Finite Element Analysis (FEA) has been widely used for this purpose, many problems are found when the numerical model is developed. Computational cost and numerical problems related to the extreme mesh distortion make the effort of finite element modelling of machining extremely time consuming. The aim of this work is to predict machinning-induced residual stresses using a finite element model based in ALE (Arbitrary Lagrangian Eulerian) approach. The finite element general-purpose code ABAQUS is used, modifying the previous model used in scientific literature to predict residual stresses. Boundary conditions in the entrance of the workpiece and in the upper border of the chip were modified from Lagrangian boundaries in the previous model, to Eulerian boundaries in the new model. Main advantages of the model presented in this work are low level of distortion of the mesh, the possibility of simulate long length of machined surface and time-efficiency. The model has been applied to calculate residual stresses in AISI 316L during machining. Reasonable agreement with experimental results has been found.