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Finite element modeling of hard turning process via a micro-textured tool

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Abstract

Literature survey showed that the micro-textures on the tool rake face can help in reduction in friction at chip-tool interface and therefore, reduction in the cutting forces. Consequently, the current work is based on FE simulation of hard turning of bearing steel (AISI52100). Four types of micro-textures have been considered on the tool rake face: non-texture, perpendicular, parallel, and rectangle. Johnson-Cook (J-C) material constitutive law has been considered for the workpiece with temperature-dependent material properties. Experimental work has been performed at cutting conditions: type, parallel; edge distance, 0.195 mm; pitch size, 0.110 mm; and height of the texture, 0.049 mm to validate the current machining model. Parametric study of effect of tool feature parameters on the cutting forces has been performed. Based on the current model, it is observed that the perpendicular shape showed the minimum cutting force. The maximum reduction of 28 % was predicted in the effective coefficient of friction compared to the non-textured surface. Additionally, effect of size of the texture (edge distance, pitch size, texture height) and the friction factor at tool-chip interface on the process responses is predicted. The perpendicular texture at an edge distance of 100 μm, pitch size of 100 μm, and texture height of 50 μm showed the most effective shape and size for the minimum cutting forces and effective friction. It is simulated that the chip flow angle can be governed by the shape/size of the texture on the tool rake face. It is expected that the current model can further be helpful in the characterization of other hard materials and complex texture shape/size.

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Authors and Affiliations

  1. Department of Mechanical Engineering, Ulsan National Institute of Science and Technology, UNIST-gil 50, Eonyang-eup, Ulju-gun, Ulsan, 689-798, Republic of Korea

    Dong Min Kim, Vivek Bajpai & Hyung Wook Park

  2. Department of Mechanical Engineering, Soongsil University, Sangdo-Ro 369, Dongjak-Gu, Seoul, 156-743, Republic of Korea

    Bo Hyun Kim

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  1. Dong Min Kim
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  2. Vivek Bajpai
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Correspondence to Hyung Wook Park.

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Kim, D.M., Bajpai, V., Kim, B.H. et al. Finite element modeling of hard turning process via a micro-textured tool. Int J Adv Manuf Technol 78, 1393–1405 (2015). https://doi.org/10.1007/s00170-014-6747-x

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