Finite element modelling of the turning of quenched steels

Abstract

The aim of the present paper is to study the capability of 
modelling by the Finite Element Method (FEM) when modelling 
behaviour of hard turning of 42CrMoS4 tempered steel, 60 HRC 
hardness, when machining with a PCBN tool. An analytical and 
experimental study has been carried out to analyse the effect 
of cutting parameters on variables such as cutting and feed 
force, temperature on the cutting zone, contact length and chip 
morphology. Initially, a flow stress model has been developed 
by carrying out dynamic and static compression tests at a 
high temperatures, obtaining the flow stress parameters to be 
implemented on the FEM model. Then, a 2D orthogonal cutting 
FEM model has been developed in the commercial software 
DEFORM. Finally, a series of experimental tests were devoted to 
the validation of the accurateness of the FEM model. In summary, 
the tendencies of the predictive model and experiments match 
in forces and temperatures. Major differences were found for 
contact length and chip thickness.