Abstract
High-strength steels, such as 42CrMo, are frequently used in a variety of technological domains for highly dynamically loaded components. In the automobile sector, there are more demands for material characteristics due to increased efficiency, performance and weight requirements. To combat this, FE simulations have been used, which reduce the need for extensive trials and have helped improve our understanding of the physical phenomena accompanying material cutting and in optimizing the cutting process. Nevertheless, the past literature lacks on evaluation of several constitutive models that can accurately simulate the oblique machining of 42CrMo. Amongst the available constitutive models, the Johnson-Cook (JC) material models has been widely used for simulating the cutting conditions for various materials. The objective of the present study is to evaluate and validate the JC model parametersperformance in simulating the machinabilitybehavior of the 42CrMo alloy. Turning experiments were conducted for medium carbon alloy steel at different cutting conditions by altering between spindle speeds of 300 rpm, 460 rpm, and 755 rpm, under constant feeds of 0.111 and 0.223 mm/rev. A numerical study was then conducted by building an FE model to simulate the turning process. The FE simulation results for cutting forces were compared with those of the experiment. The work infers that with respect to cutting forces, at medium cutting conditions, the chosen Johnson-Cook parameters provide results very close to the experimental values, but at low and high-speed cutting conditions, the model fails to predict the results accurately.
Published Version
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