Abstract: Lagrange method for the static large deformation analysis is used to establish a rigid-plastic FEM (RPFEM) analysis model based on the orthogonal cutting process of 2D plain strain hypothesis.Based on this model, an RPFEM analysis program is developed to simulate deformation of the cutting process.The whole process of orthogonal cutting is analyzed.The rule of separation between cut chips and the work piece, the criterion of separation between chip and reamer, etc., are discussed.Using the arithmetic of combining the total average weighted value of areas and that of volume, transfer of parameters between the new and old grids are realized when the grids are further divided.Simulation experiments of aluminum work pieces under normal temperature are performed, showing validity of the numeric method.

Key words: numeric simulation, chip formation, orthogonal cutting, rigid-plastic FEM