3D FEM simulation of the turning process of stainless steel 17-4PH with differently texturized cutting tools

TY - JOUR

T1 - 3D FEM simulation of the turning process of stainless steel 17-4PH with differently texturized cutting tools

AU - Liu, Guoliang

AU - Huang, Chuanzhen

AU - Su, Rui

AU - Özel, Tuğrul

AU - Liu, Yue

AU - Xu, Longhua

N1 - Publisher Copyright: © 2019 Elsevier Ltd

PY - 2019/5

Y1 - 2019/5

N2 - Micro-texturing techniques are applied to improve the performance of cutting tools by improving the tribological performance. However, sharp edges of linear micro-grooved tool designs may adversely affect tool-chip contact, create interlocking effects, and weaken the potential benefits. This paper investigates new designs in curvilinear micro-grooves on the cutting tool rake face to reduce the interlocking effect and further improve the performance. A modified methodology that uses an orthogonal cutting model and inverse analysis was utilized to determine the Johnson–Cook (J–C) constitutive material model parameters for stainless steel 17-4PH. The finite element method (FEM) simulation results in force predictions confirmed that this methodology is suitable to obtain J–C model parameters used in high-speed machining regimes. Then, three-dimensional (3D) simulations for rough and finish turning were developed and validated for machining with the non-textured cutting tool. The performance of cutting with curvilinear micro-grooved tools was investigated by 3D FEM simulations. These newly designed micro-grooved tools showed improved performance in tool-chip friction, chip formation, cutting force, temperature, and tool stress fields than non-textured and linear micro-grooved designs.

AB - Micro-texturing techniques are applied to improve the performance of cutting tools by improving the tribological performance. However, sharp edges of linear micro-grooved tool designs may adversely affect tool-chip contact, create interlocking effects, and weaken the potential benefits. This paper investigates new designs in curvilinear micro-grooves on the cutting tool rake face to reduce the interlocking effect and further improve the performance. A modified methodology that uses an orthogonal cutting model and inverse analysis was utilized to determine the Johnson–Cook (J–C) constitutive material model parameters for stainless steel 17-4PH. The finite element method (FEM) simulation results in force predictions confirmed that this methodology is suitable to obtain J–C model parameters used in high-speed machining regimes. Then, three-dimensional (3D) simulations for rough and finish turning were developed and validated for machining with the non-textured cutting tool. The performance of cutting with curvilinear micro-grooved tools was investigated by 3D FEM simulations. These newly designed micro-grooved tools showed improved performance in tool-chip friction, chip formation, cutting force, temperature, and tool stress fields than non-textured and linear micro-grooved designs.

KW - FEM

KW - Material model

KW - Micro-grooved cutting tool

KW - Stainless steel

KW - Turning

UR - https://www.scopus.com/pages/publications/85062978618

UR - https://www.scopus.com/pages/publications/85062978618#tab=citedBy

U2 - 10.1016/j.ijmecsci.2019.03.016

DO - 10.1016/j.ijmecsci.2019.03.016

M3 - Article

SN - 0020-7403

VL - 155

SP - 417

EP - 429

JO - International Journal of Mechanical Sciences

JF - International Journal of Mechanical Sciences

ER -