Finite element modeling and simulation in dry hard orthogonal cutting AISI D2 tool steel with CBN cutting tool

The influences of cutting parameters on temperature, stress, and shear angle during dry hard orthogonal cutting (DHOC) of D2 tool steel (62 +/- 1 HRC) are investigated in this paper. Temperature and stress are considered the most important aspects to be taken into account in dry hard machining; however, dry hard machining is a complex process, and the temperature fields and residual stress are the most difficult to be measured. Up to now, only very few studies have been reported on influences of cutting parameters on shear angle, temperature, and stress of AISI D2 tool steel (62 +/- 1 HRC). In this paper, the Johnson-Cook model is utilized to propose a finite element (FE) model. The FE model is properly calibrated by means of an iterative procedure based on the comparison between experimental resultant forces obtained from literatures and simulated resultant forces. At last, this FE model is utilized to predict the influences of cutting speed and depth of cut on temperature fields and residual stress within a workpiece, cutting tool edge temperature, and shear angle during DHOC hardened AISI D2 tool steel (62 +/- 1 HRC) and validated by experimental results. As shown in this investigation, it is also possible to properly analyze the influences of cutting parameters on the cutting mechanism for industrial application.