Error Analysis for Finite Element Simulation of Orthogonal Cutting and its Validation Via Quick Stop Experiments

Abstract

This work focuses on the chip formation during gun drilling of a 50CrMo4 (DIN 1.7228, AISI 4150) steel grade with a fixed set of cutting parameters and a fresh coated tool. Chip roots were investigated by means of quick stop experiments providing a measured chip width d at the chip root. Furthermore, the tool-chip contact length, L, was measured with high accuracy. Rastegaev compression tests were performed at different temperatures and strain rates for material characterization. The measured data was fit with the Johnson–Cook material model. A 2D finite element (FE) model of the orthogonal cutting process was set up starting with modelling data from literature. A parameter study was performed to determine the sensitivity of the prediction of d and L to the input parameters, i.e., the discretization, the modelling of friction and the material model. The presented error analysis of both the experimental and the numerical investigations shall serve as error estimation for similar FE simulations of the cutting process aiming at the prediction of the tool loading and/or the chip formation and breaking. Authors who have to rely on literature data may use the results presented in this work to estimate the resulting error.