Research On The Fem Simulation Of Metal Micro-cutting Process

In the process of micro-machining, the new theoretical and technological problems were put forward because of the size effect and the minimum thickness of cutting. So the traditional macro-machining theory and analysis of cutting are no longer suitable for meso-scale manufacturing process. It needs a theoretical basis for these characteristics and modeling studies to reveal the mechanism of meso scale processing.Based on the basic theories of finite element analysis and the traditional theory of cutting process, this paper produced a theoretical study on size effect and minimum cutting thickness phenomenon in the meso-scale machining process. In the view of meso-scale material mechanics, based on strain gradient theories, a novel constitutive relationship is established to model the size effect on the basis of J-C's constitutive relationship.The constitutive relationship is implanted into the DEFORM-3D FEM code by Fortran and through user routines provided by the code, which makes the DEFORM-3D FEM reflect the micro-machining process better.A simulation study is produced on cutting process by using DEFORM-3D, providing theoretical foundation for the technique and application in meso-scale cutting process.