FEM-Based Modelling of the Influence of Thermophysical Properties of Work and Cutting Tool Materials on the Process Performance

The paper considers the problem of the influence of constitutive model parameters on the results of FEM-based modelling of the turning process under simple orthogonal arrangement. In these simulations C45 (AISI 1045) carbon steel and multilayer-coated carbide tool were used. The orthogonal cutting model was used with varying cutting speed of vc=100-330 m/min and constant feed rate f=0.16 mm/rev and depth of cut ap=2 mm. The simulations were based on the power constitutive law (PL) with a special consideration of the temperature-related thermal influences. Both sets of literature data, i.e. Ozel's and Kalhori's models and own data in the form of multi-regressive equations for the substrate and coating components were applied. The novelty of this study is that the sensitivity analysis concerns the material flow stress in the PL model. As outputs, the average interface temperature, the distribution of temperature on the rake face and within wedge body, as well as cutting forces were determined, compared and discussed. Quite satisfactory results with simulation errors lower than 15% were obtained.