Development of a simulation model to study tool loads in pcBN when machining AISI 316L

Mathias Agmell, Volodymyr Bushlya, Sampsa Laakso, Aylin Ahadi, Jan-Eric Ståhl

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Abstract

This paper presents the development of a FE-simulation model to predict the mechanical stresses and thermal loads that a cutting tool of polycrystalline cubic boron nitride (pcBN) is subjected to, when machining AISI 316L. The serrated chip formation of AISI 316L has a major impact on the periodic loads acting on the cutting tool. Therefore, it is vital to correctly model this serrated chip formation. One of the major difficulties with FE-simulations of metal cutting is that the extreme deformations in the workpiece material, often leads to a highly distorted mesh. This paper uses the Coupled Eulerian-Lagrangian (CEL) formulation in Abaqus/Explicit, where the workpiece is modelled with the Eulerian formulation and the cutting tool by the Lagrangian one. This CEL formulation enables to completely avoid mesh distortion. To capture the chip serration process, the workpiece material is described with the Johnson-Cook damage model. The FE-simulation results are validated via comparison of the modelled cutting forces, chip serration frequency, and contact length against experimental ones.
Original languageEnglish
Pages (from-to)2853-2865
Number of pages13
JournalInternational Journal of Advanced Manufacturing Technology
Volume96
Issue number5-8
Early online date2018 Feb 26
DOIs
Publication statusPublished - 2018

Subject classification (UKÄ)

  • Tribology

Free keywords

  • Metal Cutting
  • FEM
  • Tool Stress
  • pcBN
  • CEL

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