A practical explicit 3D finite element analysis model has been developed and implemented to analyze turning hardened AISI 52100 steels using a PCBN cutting tool. The finite element analysis incorporated the thermo-elastic-plastic properties of the work material in machining. An improved friction model has been proposed to characterize tool-chip interaction with the friction coefficient and shear flow stresses determined by force calibration and material tests, respectively. A geometric model has been established to simulate a 3D turning. FEA Model predictions have reasonable accuracy for chip geometry, forces, residual stresses, and cutting temperatures. FEA model sensitivity analysis indicates that the prediction is consistent using a suitable magnitude of material failure strain for chip separation, the simulation gives reasonable results using the experimentally determined material properties, the proposed friction model is valid and the sticking region on the tool-chip interface is a dominant factor of model predictions.
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Technical Papers
3D FEA Modeling of Hard Turning
Y. B. Guo
School of Industrial Engineering, Purdue University, West Lafayette, IN 47907
C. R. Liu
School of Industrial Engineering, Purdue University, West Lafayette, IN 47907
Contributed by the Manufacturing Engineering Division for publication in the JOURNAL OF MANUFACTURING SCIENCE AND ENGINEERING. Manuscript received June 2000; Revised July 2001. Associate Editor: M. Elbestawi.
J. Manuf. Sci. Eng. May 2002, 124(2): 189-199 (11 pages)
Published Online: April 29, 2002
Article history
Received:
June 1, 2000
Revised:
July 1, 2001
Online:
April 29, 2002
Citation
Guo, Y. B., and Liu, C. R. (April 29, 2002). "3D FEA Modeling of Hard Turning ." ASME. J. Manuf. Sci. Eng. May 2002; 124(2): 189–199. https://doi.org/10.1115/1.1430678
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