Abstract
The machined thermal mechanical damage is a process limitation in high speed and high precision machining, especially, hard machined material of stainless steel. It is an important thing to understand the effects of process parameters on temperature distribution. This study develops an analytical and numerical model for cutting temperature prediction of AISI4340 stainless steel. The simulation model was set up in commercial FEM software of Abaqus6.8, which was good at nonlinear dynamic calculation. An ALE finite element model was used, which combines the advantages of both Lagrangian and Eulerian techniques. The Johnson-Cook plasticity model was used to model the workpiece material. This model is suitable for modeling cases with high strain, strain rates, strain hardening, and non-linear material properties. A failure criterion for chip formation was used, which ensured that the chip was twisted far away from workpiece surface. An analytical model was used to understand the temperature distribution in the primary heat source and third heat source. To satisfy the adiabatic condition of thermal mechanical theory at the workpiece boundary which contained the chip up surface and tool-worpiece surface, two imaginary heat sources were used. The temperature rise in machined workpiece is the combination of the primary and third heat sources, which the primary heat source is modeled as a uniform moving oblique band heat source and the third heat source as a non-uniform moving rectangular heat source within a semi-infinite medium. The analytical modeling and FEM modeling results match very well.
Published Version
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