The development of FEM based model of orthogonal cutting for pure iron

Abstract

The precision of cutting simualtion is determined by constitutive models, friction models, and thermal property models etc. In this study, the cutting simualtion model of pure iron with high precision is established. The power-law based material constitutive model has been developed. The high-temperature hardness tests have been carried out to acquired the item of thermal softening. The SHPB tests have been implemented to fit the items of strain hardening and strain rate strengthening. The friction model between workpiece and cutting tool has been developed by orthogonal cutting tests. The thermal property models including specific heat capacity and thermal conductivity modelshave been developed by laser flash diffusivity apparatus, which have been expressed as the functions of temperature. Orthogonal cutting tests with a wide range of cutting and cutting tool parameters have been designed, which is conducive to collecting the cutting temperature of the specific location of the cutting area. The simulated and experimental results have been compared comprehensively in the items of cutting forces and cutting temperature to verify the precision of the simulation model. It is found that the average errors of cutting force, thrust force, and cutting temperature are 5.07 %, 7.73 %, and 9.15 %, respectively, which fully proved the precision of the simulation model.