3D Finite Element Simulation of Cutting Forces in Milling Hardened Steels

Abstract

The presented work proposes a numerical 3D finite element model that is able to predict cutting forces, in hard milling of AISI 4340 steel. The numerical 3D finite element model was developed using ABAQUS/Explicit 2020 software and is based on the Lagrangian approach. Johnson-Cook strength and fracture models were adopted, to simulate the elastoplastic with isotropic hardening behavior of the workpiece material. Material's flow stress was defined in terms of strain, strain rate, and temperature. Machining tests were also carried out to verify the proposed numerical model. The close agreement between the simulated cutting forces and those that were obtained experimentally from machining tests verified the accuracy of the proposed numerical model. Chips were also collected during the machining tests and were compared to the numerically simulated ones to add another layer of validity check to the proposed numerical model.