Influence of tool geometry and numerical parameters when modeling orthogonal cutting of LFRP composites

The first objective of this paper is to analyze the influence of mesh size and shape in finite element modeling of composite cutting. Also the influence of the level of energy needed to reach complete breakage of the element is considered. The statement of this level of energy is crucial to simulate the material behavior. On the other hand geometrical characteristics of the tool have significant influence on machining processes. The second objective of the present work is to advance in the knowledge concerning tool geometry and its effect in composite cutting. A two-dimensional finite element model of orthogonal cutting has been developed and validated for Glass LFRP composite, comparing with experimental results presented in scientific literature. It was demonstrated that both numerical parameters and tool geometry influence the predicted chip morphology and machining induced damage. (C) 2011 Elsevier Ltd. All rights reserved.