Modelling orthogonal machining of carbon steels. Part II: Comparisons with experiments

Experimental measurements of cutting and thrust forces and chip shear plane angles have been carried out for six steels turned at a feed of 0.25 mm/rev at speeds from 50 to 250 m/min. The results have been successfully reproduced by finite element simulations. For this it has been necessary to include an initial yield drop from an upper to a lower yield stress in the description of the steels’ plastic strain hardening. It has also been necessary to assume flow stress to reduce non-linearly with increasing temperature in the manner proposed by Zerilli and Armstrong, up to a temperature ≈900 °C above which rapid softening takes place. A comparison is made between the present work and the earlier work of Oxley and his group.