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The present study investigated the performance of three ceramic inserts in terms of the micro-geometry (nose radius and cutting edge type) with the aid of a 3D finite element (FE) model. A set of nine simulation runs was performed according to three levels of cutting speed and feed rate with respect to a predefined depth of cut and tool nose radius. The yielded results were compared to the experimental values that were acquired at identical cutting conditions as the simulated ones for verification purposes. Consequently, two more sets of nine simulations each were carried out so that a total of 27 turning simulation runs would adduce. The two extra sets corresponded to the same cutting conditions, but to different cutting tools (with varied nose radius). Moreover, a prediction model was established based on statistical methodologies such as the response surface methodology (RSM) and the analysis of variance (ANOVA), further investigating the relationship between the critical parameters (cutting speed, feed rate, and nose radius) and their influence on the generated turning force components. The comparison between the experimental values of the cutting force components and the simulated ones demonstrated an increased correlation that exceeded 89%. Similarly, the values derived from the statistical model were in compliance with the equivalent FE model values due to the verified adequacy.

Hard turning is one of the most used machining processes in industrial applications. This paper researches critical aspects that influence the machining process of AISI-4140 to develop a prediction model for the resultant machining force-induced during AISI-4140 hard turning, based on finite element (FE) modelling. A total of 27 turning simulation runs were carried out in order to investigate the relationship between three key parameters (cutting speed, feed rate, and depth of cut) and their effect on machining force components. The acquired numerical results were compared to experimental ones for verification purposes. Additionally, a mathematical model was established according to statistical methodologies such as the response surface methodology (RSM) and the analysis of variance (ANOVA). The plurality of the simulations yielded results in high conformity with the experimental values of the main machining force and its components. Specifically, the resultant cutting force agreement exceeded 90 % in many tests. Moreover, the verification of the adequacy of the statistical model led to an accuracy of 8.8 %.