Can computer models accurately simulate the machining of hardened steel? This paper introduces a practical 3D finite element analysis (FEA) model to analyze the hard turning of AISI 52100 steel using a PCBN cutting tool. The model incorporates thermo-elastic-plastic properties of the work material and proposes an improved friction model to characterize tool-chip interaction. The research establishes a geometric model to simulate 3D turning, offering insights into chip formation, forces, residual stresses, and cutting temperatures. FEA model predictions demonstrate reasonable accuracy when compared to experimental results. Model sensitivity analysis confirms that the magnitude of material failure strain for chip separation gives consistent results using experimentally determined material properties. The analysis also validates the proposed friction model and highlights the significant influence of the sticking region on the tool-chip interface on model predictions. This study provides a valuable tool for optimizing hard turning processes. By accurately predicting key parameters, the FEA model has the potential to reduce manufacturing costs, improve product quality, and enable the development of more efficient machining strategies for hardened steels. This tool contributes to advancements in manufacturing engineering, offering significant implications for the machining industry.
The Journal of Manufacturing Science and Engineering emphasizes innovative research in manufacturing processes, making this paper a strong fit. The development and validation of a 3D FEA model for hard turning directly aligns with the journal's focus. By improving understanding and prediction in machining, this research contributes to advancing manufacturing science and engineering practices.