Effect of cutting edge microgeometry on surface roughness and white layer in turning AISI 52100 steel

Abstract

Abstract In high precision cutting, cutting edge microgeometry largely influences the machining performance and wear behavior of cutting tool. This study systematically analyses the effect of cutting edge microgeometry on surface roughness and white layer formation. A series of orthogonal cutting experiments of AISI 52100 steel is established with various edge preparations. Meanwhile, 2D finite element cutting model based on ABAQUS/EXPLICIT general software is developed to investigate the formation of white layer. In the proposed numerical model, the Johnson-Cook constitutive model is used to describe the elastic and plastic deformation of machined surface layer. Then, surface topography of machined workpiece is achieved to get 2D surface roughness. Besides, the phase transition mechanism with the consideration of the combination of stress and strain is used to predict the white layer. The investigation results show that enlarging chamfer width can improve surface roughness, while increasing chamfer angle has less effect on surface roughness. Moreover, both large rounded edge and large chamfered edge can contribute to white layer formation.