Modelling orthogonal and oblique cutting via discontinuity layout optimization

The discontinuity layout optimization (DLO) numerical modelling procedure is used to model the slip-line fields associated with plastic deformation and chip formation in metal cutting operations. A series of orthogonal and oblique cutting operations at low and high cutting speeds are simulated, with modelling results validated against key cutting parameter data from machining trials (cutting forces, chip morphology etc.). Reasonably good correlation between the predicted and experimental outputs is obtained, suggesting that the DLO method may provide a viable alternative to traditional methods such as incremental finite element analysis.