In recent years, the applications of finite element
method (FEM) in metal cutting operations have proved to
be effective in studying the cutting process and
manufacturing process. The simulation result is useful for
both researchers and tool makers to optimize the cutting
process by designing new tools. Simulation and modelling
were performed in two-dimensional and threedimensional
for designing the new component prior to fabricating. These are very useful for reducing time and cost consumption in designing automotive parts. The FEM simulation just only requires computational tool and FEM simulation package. The present work aims to predict of performance three-dimensional orthogonal of cutting operations using FEM software (Deform-3D). Some important information such as cutting force, stress, strain and generated temperature during machining process were studied and analysed. Orthogonal cutting simulations were conducted to study the effect of cutting speed, feed rate and depth of cut on the cutting force, the effective-stress, strain and generated temperature in turning process. FCD 500 (ductile cast iron) was used as the work material and cutting tool was DNMA 432
(uncoated carbide tool, SCEA = 0; BR = -5; SR = -5 and
radius angle 55o). The cutting parameters varied were
cutting speed (100 m/min, 150 m/min and 200 m/min), feed
rate (0.1, 0.25 and 0.4 mm/rev), and depth of cut (DOC)
(0.3, 0.6 and 0.9 mm). The performance was showed by the
simulation results that show by increasing the cutting
speed, it causes decreasing in cutting force, effective stress and strain, but the generated temperature during the chip formation process increases. High value of feed rate
resulted in bigger cutting force, stress, strain and
generated temperature. In addition, bigger cutting force
and high generated temperature occurred at high depth of
cut
