Finite element analysis to study the effects of the workpiece flow stress models on cutting variables in orthogonal cutting

Abstract EN

Turning process is a common machining process to produce cylindrical shape parts.

Understanding of material removal concepts in metal cutting is very important in design process and cutting tool selection to ensure the quality of the products.

For this purpose, orthogonal cutting simulations of AISI 1045 steel are performed and the model used in simulations is validated.

Effects of work piece flow stress models on cutting variables such as cutting forces, chip geometry and temperature are investigated by comparing simulation results with experimental results available in the literature.

Results show that flow stress models have a major effect on calculated results.

The results of the simulations show that Oxley material model is able to give more accurate results for used cutting conditions in the analysis, however errors in calculating shear angle and thrust force are higher than Johnson-cook and Zerilli-Armstrong material models.