Surface integrity is extremely affected by manufacturing processes conditions especially the evolution of cutting tool performance. Many researchers, in steel machining field, focused their works on the elaboration of models predicting tool wear combining both numerical and experimental approaches. Most of published numerical cutting models simulate the chip formation for a few micro to millisecond time periods. For that, all corresponding experimental tests, needed for the model validation, are usually carried-out in special time conditions which is not reflecting industrial situations. Indeed, the latters are characterized by tool wear whose evolution can affect extremely cutting force levels and the final workpiece integrity. In this context, the main purpose of the proposed research work is to develop a FEM model, based on the commercial code ABAQUSO, to simulate wear phenomenon of tool insert in the case of orthogonal cutting operation. The present research exposes a lagrangian approach simulating the chip formation in the case of AISI4140 machining. A strategy that aims to reach high machining time simulated with moderate computational time is presented. It is based on ensuring the thermal continuity of the tool from one calculation to another. A considerable gain of calculation time is achieved comparing to the most common models developed on ABAQUS?.
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