Analyzing the use of rigid- or elastic-plastic finite models for the simulating of cutting processes

The simulation modeling of cutting processes represents a powerful scientific instrument for investigating stress-strain and thermodynamic processes in machined materials. Nevertheless, the principal obstacle to the extensive deployment of this scientific approach is inadequate precision of the resulting research outcomes. This is due to the complexity of formalizing the physical and mechanical forming pattern, considering all the dominant factors in building a high-quality cutting model. Additionally, there is a need for professional experience from the researcher to correctly describe the physical model of the material, as well as a logical selection of fracture criteria, among other factors. One of the most significant challenges in ensuring the accuracy of cutting modeling processes is formalization of the description of a rigid-plastic or elasto-plastic FEA model for analyzing the behavior of materials during machining. The article presents a scientifically based argument for the practicality of using these techniques in simulation modeling systems. It also provides practical recommendations for researchers on constructing an accurate FEA simulation model in DEFORM 2D. The conclusions drawn from the analysis of simulation studies of cutting-induced residual stresses for heterogeneous materials are confirmed by experimental investigations.