Title: Coupled thermo-mechanical FEM-based modelling of the tool-chip contact behaviour for coated cutting tools

Authors: W. Grzesik; P. Nieslony

Addresses: Department of Manufacturing Engineering and Production Automation, Opole University of Technology, P.O. Box 321, 45-271 Opole, Poland. ' Department of Manufacturing Engineering and Production Automation, Opole University of Technology, P.O. Box 321, 45-271 Opole, Poland

Abstract: This study explores two variants of the FEM simulation model of orthogonal cutting process of AISI 1045 carbon steel with uncoated and multilayer-coated carbide tools, i.e., standard and power law-temperature dependent (PL-TD) options. The primary reason for undertaking this problem was unsatisfactory accuracy of the predictions of the cutting temperature and other thermal characteristics especially for coated cutting tools. Multi-layer coating is substituted by homogeneous monolithic layer with equivalent thermal properties. In addition, these simulation algorithms use material constitutive law comparable to the Johnson-Cook constitutive law. Basically, the FEM package applied allows the temperature distribution and heat flux intensity to be predicted closer to appropriate measurements and analytical computations. Originality of this simulation approach can be seen in elaborating more accurate models with updated thermal properties. Particularly, it contributes to predicting some fundamental relationships between all physical phenomena involved into the overall tool-chip contact behaviour.

Keywords: orthogonal cutting; thermal behaviour; contact stress; FEM; finite element method; simulation; coated cutting tools; thermomechanical modelling; tool-chip contact; carbon steel; carbide tooling; cutting temperature; temperature distribution; heat flux intensity.

DOI: 10.1504/IJMMM.2012.044920

International Journal of Machining and Machinability of Materials, 2012 Vol.11 No.1, pp.20 - 35

Received: 20 Jul 2010
Accepted: 22 Sep 2010
Published online: 23 Aug 2014 *

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