3D FEM simulation of the turning process of stainless steel 17-4PH with differently texturized cutting tools

Micro-texturing techniques are applied to improve the performance of cutting tools by improving the tribological performance. However, sharp edges of linear micro-grooved tool designs may adversely affect tool-chip contact, create interlocking effects, and weaken the potential benefits. This paper investigates new designs in curvilinear micro-grooves on the cutting tool rake face to reduce the interlocking effect and further improve the performance. A modified methodology that uses an orthogonal cutting model and inverse analysis was utilized to determine the Johnson-Cook (J-C) constitutive material model parameters for stainless steel 17-4PH. The finite element method (FEM) simulation results in force predictions confirmed that this methodology Is suitable to obtain J-C model parameters used in high-speed machining regimes. Then, three-dimensional (3D) simulations for rough and finish turning were developed and validated for machining with the non-textured cutting tool. The performance of cutting with curvilinear micro-grooved tools was investigated by 3D FEM simulations. These newly designed micro-grooved tools showed improved performance in tool-chip friction, chip formation, cutting force, temperature, and tool stress fields than non-textured and linear micro-grooved designs.