Eulerian finite element analysis of 3D machining

V. Madhavan, L. Olovsson, S. C. Swargam, R. Agarwal

Research output: Chapter in Book/Report/Conference proceedingConference contributionpeer-review

3 Scopus citations


We describe here the development and testing of a capability for finite element simulation of practical machining operations such as turning and milling, using 3D multi-material, explicit dynamic, Eulerian finite element analysis. In these simulations the workpiece material and the air surrounding it are modeled using Eulerian finite elements and the flow of the workpiece material into the air as a result of the action of the Lagrangian tool can be freely tracked. Tension tests and Taylor impact tests are simulated using the traditional Lagrangian approach as well as the Eulerian approach. Comparison of the results is used to understand the factors affecting the solution accuracy. Simulations of orthogonal machining using this technique show that the side flow of the chip is simulated realistically. Simulations of oblique machining with various rake and inclination angles confirm that the chip flow angle is independent of the rake angle. Inertial effects cause the chip flow angle to differ from the inclination angle as the weight of the chip increases. Simulations of turning and end milling show that chip formation and flow can be simulated ab-initio. The simulation capability described here can provide accurate results for various outputs of interest and is also computationally efficient, allowing a typical analysis to be completed within a day.

Original languageEnglish
Title of host publicationAmerican Society of Mechanical Engineers, Fluids Engineering Division (Publication) FED
Number of pages7
ISBN (Print)0791816613
StatePublished - 1999
EventFluids Engineering Division - 1999 (The ASME International Mechanical Engineering Congress and Exposition) - Nashville, TN, USA
Duration: Nov 14 1999Nov 19 1999


ConferenceFluids Engineering Division - 1999 (The ASME International Mechanical Engineering Congress and Exposition)
CityNashville, TN, USA


Dive into the research topics of 'Eulerian finite element analysis of 3D machining'. Together they form a unique fingerprint.

Cite this