Date of Award


Publication Type

Master Thesis

Degree Name



Electrical and Computer Engineering

First Advisor

Alpas, A. T.


Engineering, Materials Science.




The aim of the present work was to develop a finite element model for the prediction of the deformation state of copper subjected to orthogonal cutting. Research completed in the present work showed that the Eulerian element formulation was the most effective in modeling metal cutting, especially when the hydrodynamic material model was employed to represent the workpiece. The following correlations were drawn between the experimental findings and the numerical model employing the hydrodynamic material: (1) The maximum experimental stress (sigma = 422 MPa) and strain (epsilon p = 8.1) were located at the tool tip and corresponded well with the numerical results, which predicted a maximum strain of 5.6 and maximum stress of 410 MPa also at the tool tip. (2) The stresses and strains along the primary shear plane were found to decrease from a maximum at the tool tip to a minimum at the chip root, in both experimental and numerical observations. (3) An increase in strain and stress was detected beneath the machined surface and adjacent to the rake face in the numerical model. The maximum stress and strain in the machined surface, predicted as 3.5 and 360 MPa, respectively, were within 5% of the experimental results. The secondary deformation zone contained similar numerical stresses and strains. (4) The sizes of both the primary deformation zone (600 mum), and the secondary deformation zone (80 mum) predicted by the hydrodynamic material model were in good agreement with the experimental observations. (5) Overall the numerical stress and strain values were within 5--25% of the experimental findings. (Abstract shortened by UMI.)Dept. of Electrical and Computer Engineering. Paper copy at Leddy Library: Theses & Major Papers - Basement, West Bldg. / Call Number: Thesis2004 .R33. Source: Masters Abstracts International, Volume: 43-01, page: 0298. Advisers: Ahmet Alpas; William Altenhof. Thesis (M.A.Sc.)--University of Windsor (Canada), 2004.