Abstract
The white layer formed during hard turning deteriorates surface integrity, thereby severely affecting the fatigue life of machined parts. A 2D FEM-based simulation model has been developed to simulate cutting temperature profiles in workpieces for the prediction of white layer thickness developed below the machined surface. Machining was simulated for fresh and worn tools with predefined flank wear. The temperature profile generated in the workpiece was analyzed for the critical temperature for phase transformation leading to white layer formation. The critical temperature was found to be deeper in the subsurface with an increase in cutting speed and wear, indicating a thicker subsurface white layer. Experimental observations using fresh tools were found very close to the simulation results. The model was extended to simulate temperature profile and predict the white layer for machining with tools having predefined tool flank wear.
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