Finite Element Analysis Of Influence Of Flank Wear Evolution On Forces In Orthogonal Cutting Of 42CrMo4 Steel

Abstract

A B S T R A C TThis paper presents analysis of flank wear influence on forces in orthogonal turning of 42CrMo4 steel and evaluates capacity of finite element model to provide such force values. Data about magnitude of feed and cutting force were obtained from measurements with force tensiometer in experimental test as well as from finite element analysis of chip formation process in ABAQUS/Explicit software. For studies an insert with complex rake face was selected and flank wear was simulated by grinding operation on its flank face. The aim of grinding inset surface was to obtain even flat wear along cutting edge, which after the measurement could be modeled with CAD program and applied in FE analysis for selected range of wear width. By comparing both sets of force values as function of flank wear in given cutting conditions FEA model was validated and it was established that it can be applied to analyze other physical aspects of machining. Force analysis found that progression of wear causes increase in cutting force magnitude and steep boost to feed force magnitude. Analysis of Fc/Ff force ratio revealed that flank wear has significant impact on resultant force in orthogonal cutting and magnitude of this force components in cutting and feed direction. Surge in force values can result in transfer of substantial loads to machine-tool interface.

Mechanics of Grains Size and Orientation on the Machining of AISI S-7 Steel Grade Using Numerical Technique

“…Simulation techniques with finite element codes have been consistently proven and successfully executed on different grades of steel viz. 42CrMo4 Steel, carbide tool, Ti6Al4V Alloys, Al6061-T6 and were found give very promising results [1,2,3,4]. For the understanding of chip morphology and its effect on tool wear, a number of featured models in FEA have been tried, namely Lagrangian formulation: includes nodes formation criterion to predict chip separation, lagrangian description of motion and adaptive remeshing: applied to simulate orthogonal cutting , Finite Element Eulerian formulations: to simulate continuous chip formation at steady state, Finite Element Arbitrary Lagrangian-Eulerian (ALE) the formulation in conjunction with adaptive mesh techniques etc.…”