Modelling Requirements for Computer Simulation of Metal Machining

Machining modelling efforts are summarised and some important shortcomings of these are presented. The reasons for these shortcomings have been investigated. The investigations are based on machining simulation research and accompanying experimental studies. The reasons are found to be mainly in the approaches taken towards modelling the mesh and boundary conditions, the flow stress of the workpiece material and the frictional properties at the interface between the chip and the cutting tool. The handlings of the extremely high temperature increases and the mechanism taking place during separation of the chip from the workpiece by the tool are also among the significant reasons. The aim of this paper is to present some solutions towards modelling these aspects of machining.