FEM-based investigation on machining forces and temperatures induced during AISI-4140 hard turning

Abstract

Turning is probably one of the most common machining processes used to manufacture parts for the industrial sector. In order to reduce development times and costs during turning, it is necessary to employ methodologies and techniques that enable the precise prediction of the important parameters that relate to the process. Such a methodology is the implementation of Finite Element Method (FEM). In this work, the 3D modelling of AISI-4140 hard turning with ceramic tooling is being presented by utilizing the DEFORM-3D™ Finite Element Analysis (FEA) software system. Nine tests were conducted according to typical cutting conditions as recommended by tool manufacturers; cutting speed of 80 m/min, 115 m/min and 150 m/min and feed of 0.08 mm/rev, 0.11 mm/rev and 0.14 mm/rev, at a constant depth of cut equal to 0.30 mm. The developed friction forces, heat transfer and contact interface stresses between the tool and the workpiece were approximated with the aid of well-established models to simulate the machining mechanisms. Additionally, a validation of the yielded results for the machining components and the temperature distribution was performed by comparing the numerical results with experimental data. Most of the simulations generated results in agreement with the experimental ones. The agreement percentage exceeds 90% in most tests for the investigated components (machining forces and temperature), confirming both the validity and the accuracy of the model.