An improved thermomechanical modeling for orthogonal cutting of AISI 1045 steel

Abstract

In this paper, two Finite Elements (FE) models with different boundary conditions and mesh constraints were developed for orthogonal cutting of AISI 1045 steel by using an Arbitrary Lagrangian-Eulerian (ALE) approach, which allows the absence of the damage criterion and element distortion. We used a Johnson-Cook (J-C) rheological law for the behavior of the work material and a Coulomb's model for the friction at the tool-chip interface. The simulation results were confronted, on the one hand, with experimental data and, on the other hand, with those obtained by thermomechanical analytic modeling. For this last context, some corrections have been made to Oxley's theory by taking into account a non-uniform distribution of the stresses at the tool-chip interface. For this, the normal stress distribution is modeled with a power-law relationship, and tangential stress is weighted by a corrective coefficient. The models evaluation focused on the components of the machining force, the temperature at the tool-chip interface and chip thickness; close agreements with the experiments were observed.

Keywords

• Thermomechanical modeling
• Orthogonal cutting
• FE model
• ALE approach
• Simulation
• AISI 1045 steel