Modeling and Characterization of Aisi S-7 Steel Using the Johnson Cook Model – an Explicit Analysis

Abstract

: A two dimensional, uniformly distributed grains model has been developed for AISI S-7 grade Steel and the orthogonal machining process, in the pursuit of determining the various effects of temperature rise, residual stresses, chip morphology, and strain hardening. A Johnson-Cook material model, along with a numerical, technique was used to simulate the machining process using ANSYS 15 academic license. The machining has been carried out at different velocities: 60, 70, and 80 ms-1 and with depths of cut of 2, 3, and 5 mm. Results revealed that the accumulation of tandem grains offers a maximum resistance ahead of the tool-chip interface due to the strain hardening effect, during the metal removal process. This effect leads to a maximum rise in temperature up to 912.59 °C, which has been observed in the secondary shear zone. Serrated chip flow was observed mainly at a low speed of 60 ms-1. The Strain hardening effect was more substantial at 60 ms-1 and 5 mm depth of cut compared to any other machining parameters. A great deal of discussion has been made on the above material machining process that may serve as a useful resource to the tool designer and manufacturing scientist.