Development of a simulation model to study tool loads in pcBN when machining AISI 316L

Mathias Agmell,Volodymyr Bushlya,Aylin Ahadi,Sampsa V A Laakso,Jan-Eric Ståhl

doi:10.1007/s00170-018-1673-y

Mathias Agmell, Volodymyr Bushlya + Show 3 more

Open Access

https://doi.org/10.1007/s00170-018-1673-y

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Abstract

This paper presents the development of a FE-simulation model to predict the mechanical stresses and thermal loads that a cutting tool of polycrystalline cubic boron nitride (pcBN) is subjected to, when machining AISI 316L. The serrated chip formation of AISI 316L has a major impact on the periodic loads acting on the cutting tool. Therefore, it is vital to correctly model this serrated chip formation. One of the major difficulties with FE-simulations of metal cutting is that the extreme deformations in the workpiece material, often leads to a highly distorted mesh. This paper uses the Coupled Eulerian-Lagrangian (CEL) formulation in Abaqus/Explicit, where the workpiece is modelled with the Eulerian formulation and the cutting tool by the Lagrangian one. This CEL formulation enables to completely avoid mesh distortion. To capture the chip serration process, the workpiece material is described with the Johnson-Cook damage model. The FE-simulation results are validated via comparison of the modelled cutting forces, chip serration frequency, and contact length against experimental ones.

Highlights

Introduction lrContact length on the rake face mThermal softening coefficient in Johnson-CookCemented carbide is the most common material for tooling nStrain hardening exponent in Johnson-Cook PHydrostatic stress (N/mm2)in metal cutting [29]
The focus of this paper is to examine the possibility to use the Coupled EulerianLagrangian (CEL) formulation to model a serrated chip formation
This study shows that the CEL formulation is a promising technique to use when studying mechanical and thermal loads acting on a cutting tool in 3D

Summary

Introduction

Introduction lrContact length on the rake face (mm) mThermal softening coefficient in Johnson-CookCemented carbide is the most common material for tooling nStrain hardening exponent in Johnson-Cook PHydrostatic stress (N/mm2)in metal cutting [29]. Contact length on the rake face (mm) m. Cemented carbide is the most common material for tooling n. Strain hardening exponent in Johnson-Cook P. in metal cutting [29]. Tungsten and cobalt, are classified as critical raw materials [3], and rβ. Edge radius mm a search for alternative tooling, like polycrystalline rε. Nose radius mm cubic boron nitride (pcBN), is on an industrial agenda. Tcl. Tangential force acting on the clearance face (N) Eighteen percent of cemented carbide is used for machining

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