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Finite element modeling of hard turning

Al-Zkeri, Ibrahim Abdullah

Abstract Details

2007, Doctor of Philosophy, Ohio State University, Mechanical Engineering.
During hard turning, the cutting tool is exposed to a very severe environment due to the hardness of the machined steels and the small contact area between the tool and the workpiece. Moreover, the residual stress patterns that are generated near the machined surface are influenced by many factors such as process variables, tool wear, and cutting edge preparation. For a tool to perform successfully under these severe conditions and for an enhanced surface integrity, factors such as the cutting tool edge geometry, feed rate, and cutting speed have to be carefully selected. In this study, the two-dimensional finite element method (FEM) is used as a tool for understanding the fundamentals of hard turning process and for predicting the effect of CBN tool edge preparation (edge hone radius, chamfer angle) and cutting conditions (cutting speed, feed rate) on the hard turning variables (cutting forces, chip morphology, tool stresses and temperature, and residual stresses). In addition, a methodology for obtaining flow stress data for machining simulations from machining and compression tests has been developed. The flow stress data that are obtained using this methodology provided better predictions of hard turning variables than other flow stress data obtained from a single test for the same cutting conditions. Practical hard turning is a 3D process. Hence, using the new enhancement to computers and software, two numerical methods are used to study the 3D hard turning process: 1) simplification of the 3D hard turning process using an analytical model and 2D FEM and 2) 3D FEM. While the methodology used to represent the 3D cutting process of AISI 4340 in a 2D process gives results close to the values predicted using 3D cutting simulation, it provides predictions of cutting forces that are lower than the measured forces. On the other hand, the modeling of hard turning of AISI 52100 using 3D FEM gives close predictions of cutting force but not of the depth and feed force. However, the simulations ran smoothly and the use of more reliable flow stress data and finer mesh for the workpiece are expected to improve the predictions.
Taylan Altan (Advisor)
245 p.

Recommended Citations

Citations

  • Al-Zkeri, I. A. (2007). Finite element modeling of hard turning [Doctoral dissertation, Ohio State University]. OhioLINK Electronic Theses and Dissertations Center. http://rave.ohiolink.edu/etdc/view?acc_num=osu1181928433

    APA Style (7th edition)

  • Al-Zkeri, Ibrahim. Finite element modeling of hard turning. 2007. Ohio State University, Doctoral dissertation. OhioLINK Electronic Theses and Dissertations Center, http://rave.ohiolink.edu/etdc/view?acc_num=osu1181928433.

    MLA Style (8th edition)

  • Al-Zkeri, Ibrahim. "Finite element modeling of hard turning." Doctoral dissertation, Ohio State University, 2007. http://rave.ohiolink.edu/etdc/view?acc_num=osu1181928433

    Chicago Manual of Style (17th edition)