Numerical chip formation simulations of AISI 304 steel with varying cutting tools

Abstract

Numerical chip formation simulations are a promising approach for determining the tool wear behavior of cemented carbide tools in a resource-efficient way. To achieve a high prediction quality of the chip formation simulations, suitable input data must be identified with regard to the friction and flow stress behavior of the material. Therefore, within this work, the flow stress and frictional behavior was first determined experimentally. Based on the investigations a numerical chip formation simulation was parameterized for future wear simulations. Beside the Split Hopkinson Pressure Bar (SHPB) test, quasi-static compression tests were conducted to characterize the flow stress behavior of the workpiece material. Furthermore, the frictional behavior was investigated using a special machine tool for fundamental chip formation analysis, taking into consideration the relative speed and measuring the contact temperatures for uncoated and TiAlN coated cutting tools. Based on the experimental data, different models for flow stress and friction were parameterized. Subsequently the models were implemented into the numerical chip formation simulation to model the thermo-mechanical load collective, whereas the results by means of the resulting forces were validated by orthogonal cutting tests. The parameterization of the friction models led to an improved prediction quality of the numerical chip formation simulation with regard to the cutting forces in comparison to a constant friction model.