Skip to main content
SpringerLink
Log in

Orthogonal cutting of hardened AISI D2 steel with TiAlN-coated inserts—simulations and experiments

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

This paper presented a finite element simulation model for the analysis of AISI D2 steel turning with TiAlN-coated inserts. In this study, material constitutive model of hardened AISI D2 steel (HRC62) was built based on power law relationship, which was used in the FEM codes to describe the effect of strain, strain rate, and temperature on the material flow stress. A damage model was employed to predict the chip separation. Cutting edge radius and thickness of TiAlN coating were obtained by micro-optical system and SEM, respectively. The average friction coefficients were obtained by ball-on-disk friction test using UMT-2 high-speed tribometer. Numerical simulations of AISI D2 steel turning were performed using AdvantEdge™ software. The simulated results of forces and chip morphology showed good agreement with the experimental results, which validated the precision of the process simulation method. The shear stress on the interface between coating and substrate of cutting tool was analyzed. And the maximal shear stress between coating and substrate was found on the cutting edge roundness near the flank face of cutting tool.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Similar content being viewed by others

References

  1. Grzesik W, Bartoszuk M, Nieslony P (2005) Finite element modelling of temperature distribution in the cutting zone in turning processes with differently coated tools. J Mater Process Technol 164–165:1204–1211

    Article  Google Scholar 

  2. Grzesik W, Bartoszuk M, Nieslony P (2004) Finite difference analysis of the thermal behaviour of coated tools in orthogonal cutting of steels. Int J Mach Tools Manuf 44:1451–1462

    Article  Google Scholar 

  3. Brito RF, Carvalho SR, Silva SMML et al (2009) Thermal analysis in coated cutting tools. Int Commun Heat Mass 36:314–321

    Article  Google Scholar 

  4. Kone F, Czarnota C, Haddag B et al (2011) Finite element modelling of the thermo-mechanical behavior of coatings under extreme contact loading in dry machining. Surf Coat Tech 205:3559–3566

    Article  Google Scholar 

  5. Qin F, Chou YK, Nolen D et al (2009) Coating thickness effects on diamond coated cutting tools. Surf Coat Tech 204:1056–1060

    Article  Google Scholar 

  6. Bouzakis KD, Michailidis N, Hadjiyiannis S et al (2001) Improvement of PVD coated inserts cutting performance, through appropriate mechanical treatments of substrate and coating surface. Surf Coat Tech 146–147:443–450

    Article  Google Scholar 

  7. Bouzakis KD, Hadjiyiannis S, Skordaris G et al (2004) The effect of coating thickness, mechanical strength and hardness properties on the milling performance of PVD coated cemented carbides inserts. Surf Coat Tech 177–178:657–664

    Article  Google Scholar 

  8. Özel T (2006) The influence of friction models on finite element simulations of machining. Int J Mach Tools Manuf 46:518–530

    Article  Google Scholar 

  9. Bil H, Kilic SE, Tekkaya AE (2004) A comparison of orthogonal cutting data from experiments with three different finite element models. Int J Mach Tools Manuf 44:933–944

    Article  Google Scholar 

  10. Jiang F, Li JF, Rong YM et al (2008) Study of cutting temperature in cold-air milling of Ti6Al4V alloy. In: Mamoru M, Kanji U, Fumihiko K (eds) 41st CIRP conference on manufacturing system. Tokyo, Japan, pp 371–376

    Google Scholar 

  11. Movahhedy MR, Gadala MS, Altintas Y (2000) FE modeling of chip formation in orthogonal metal cutting process: an ALE approach. Mach Sci Technol 4:15–47

    Article  Google Scholar 

  12. Movahhedy MR, Altintas Y, Gadala MS (2002) Numerical analysis of metal cutting with chamfered and blunt tools. J Manuf Sci E-T ASME 124:178–188

    Article  Google Scholar 

  13. Adibi-Sedeh AH, Madhavan V (2003) Understanding of finite element analysis results under the framework of Oxley’s machining model. 6th CIRP International Workshop on Modeling of Machining Operations. McMaster University, Hamilton

  14. Becze CE (2001) A thermo-mechanical force model for machining hardened steel. Ph.D. thesis, McMaster University

  15. Jiang F, Li JF, Sun J et al (2010) Al7050-T7451 turning simulation based on the modified power-law material model. Int J Adv Manuf Technol 48:871–880

    Article  Google Scholar 

Download references

Author information

Authors and Affiliations

  1. The State Key Laboratory of Tribology, Tsinghua University, Beijing, China

    Feng Jiang, Lan Yan & Yiming Rong

  2. Department of Precision Instruments and Mechanology, Tsinghua University, Beijing, China

    Feng Jiang, Lan Yan & Yiming Rong

Authors
  1. Feng Jiang
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Lan Yan
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Yiming Rong
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Feng Jiang.

Rights and permissions

Reprints and permissions

About this article

Cite this article

Jiang, F., Yan, L. & Rong, Y. Orthogonal cutting of hardened AISI D2 steel with TiAlN-coated inserts—simulations and experiments. Int J Adv Manuf Technol 64, 1555–1563 (2013). https://doi.org/10.1007/s00170-012-4122-3

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-012-4122-3

Keywords

Search

Navigation