Intro
Contents
1 A Comparative Study Between 2D and 3D Finite Element Methods in Machining
1.1 Introduction
1.2 Comparison Between 2D and 3D FEM Analysis Techniques
1.2.1 Evaluation of Cutting Forces and Torque
1.2.2 Chip Formation and Dimensions Assessment
1.2.3 Examination of Residual Stresses
1.2.4 Temperature and Tool-Wear Assessment
1.3 Conclusions
References
2 Fundamentals of 3D Finite Element Modeling in Conventional Machining
2.1 Introduction
2.1.1 FEM-Based Studies in Machining
2.1.2 Advantages and Limitations of FEM

2.2 Finite Element Modeling in Machining
2.2.1 Meshing and Element Types
2.2.2 Mesh Adaptivity
2.2.3 Tool-Workpiece Representation
2.2.4 Boundary Conditions
2.2.5 Material Flow Stress Modeling
2.2.6 Friction Modeling and Contact Description
2.2.7 Material Separation
2.2.8 Tool Wear
2.3 Typical FEM-Based Results
2.3.1 Cuttings Forces, Torque, and Residual Stresses
2.3.2 Chip Morphology, Temperature Distribution, and Wear
2.4 Conclusions and Perspectives
References
3 FEM-Based Study of AISI52100 Steel Machining: A Combined 2D and 3D Approach

3.1 Introduction
3.2 Materials and Methods
3.2.1 Machining Process Framework
3.2.2 Preliminary FE Model Assessment
3.2.3 Numerical Modeling of the Turning Process in Three Dimensions
3.3 Results and Findings
3.3.1 Machining Forces Evaluation
3.3.2 Chip Geometry Evaluation
3.4 Conclusions
References
4 Experimental and 3D Numerical Study of AA7075-T6 Drilling Process
4.1 Introduction
4.2 Materials and Methods
4.2.1 Layout of Experimental Testing
4.2.2 Finite Element Layout
4.3 Results and Findings
4.3.1 Cutting Forces and Torque Analysis

4.3.2 Chip Morphology Analysis
4.3.3 Temperature Distribution Analysis
4.3.4 Concluding Remarks
References
5 3D Finite Element Simulation of CK45 Steel Face-Milling: Chip Morphology and Tool Wear Validation
5.1 Introduction
5.2 Materials and Methods
5.2.1 Experimental Framework
5.2.2 Face-Milling CAD-Based Setup
5.2.3 Numerical Modeling of the Face-Milling Process
5.3 Results and Discussion
5.3.1 Chip Formation Analysis and Temperature Distribution Evaluation
5.3.2 Tool Wear Assessment
5.4 Concluding Remarks
References