Journal
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
Volume 64, Issue 9-12, Pages 1555-1563Publisher
SPRINGER LONDON LTD
DOI: 10.1007/s00170-012-4122-3
Keywords
Finite element simulation; Chip morphology; Turning forces; Shear stress; Coating/substrate interface
Funding
- National Natural Science Foundation of China [51,105,224]
- National Basic Research Program of China [2011CB013404]
- China Postdoctoral Science Foundation [20,110,490,380, 20,110,490,383]
- State Key Laboratory of Tribology, Tsinghua University [SKLT10A01]
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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 (TM) 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.
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