Studies on wears of ultrafine-grained ceramic tool and common ceramic tool during hard turning using Archard wear model

Hardened steels are difficult to be machined due to their high tensile strength and work-hardening rate, low thermal conductivity, and abrasive behavior. In this paper, finite element modeling (FEM) approaches with lagrangian increment method for 3D metal turning of hardened steel H13 by common ceramic tool and ultrafine-grained tool respectively have been investigated by simulation of DEFORM-3D software and turning test. Conditions of initial and boundary and turning process parameters have been chosen. Material properties of H13 and ceramic have been described in details. Johnson-Cook model of H13 model has been applied to the hard turning modeling. Archard wear model has been built, and the correlation coefficients were decided by reciprocating friction experiments. The simulation results showed that predicted primary turning force and maximum temperature in common ceramic are bigger than which was caused by ultrafine-grained ceramic tool for the ultrafine-grained ceramic tools have better thermal stability and bigger hardness. The wear depths of common ceramic tool are about many times than that of ultrafine-grained ceramic tool according to the simulation and experimental results. And their wear patterns are very different. The FEM simulation results have entirely explicated experimental results. The obtained results would provide the fundamental and practical guidelines of tool material choice for hard turning.