I have made a Dynamic explicit analysis of 2D metal cutting operation with Abaqus. I have plotted the reaction force in X axis of the node at the tool tip.
I had run a similar simulation with different velocity (120m/min , 60 m/min ) and got the reaction force at the same node.
The two graphs seem to differ drastically , with one plot consistent with experimental cutting force plot and the other different from it.
Can anyone tell me what I am doing wrong ?
dear Vignesh Narayan, it would be helpful if you could provide more details about your model setup (tool shape, material properties, mesh, meshing details a.s.o.). If modeling errors can be excluded, changes in the deformation fields for both cases can lead to different stress and strain distributions (acutally they even should) and hence specific nodes of compression forces change to states of tensile stress or vice versa. On the other hand 60 and 120 m/min are both rather low cutting speeds.
If the answer somehow helped , vote it up.
I think your results are very reasonable, if you increase velocity then force increases too.
The force in the second graph is too low, also can you run the model for a longer period of time to observe the force profile over longer period of time.
Normally, when you increase the cutting speed, the force decrease, because of the temperature increase and, the cutting stress decrease. I know this because I work a lot of time in this sense.
But the difference may be in the range of -10% to -30%. The difference that you obtain by simulation is not possible.
Thank you all for all the answers. It helped me a lot. I found out what I was doing wrong. I was measuring reactionforce at a single node at tool tip. All I had to do was measure the forces at all nodes and get an average of all. I got similar cutting force plot for different speeds and also the values were consistent.
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