Study On FE Simulation Of Chip Formation And Temperature Field During High Speed Machining Hardened Steel

The high speed machining has become the important component of the modern advanced manufacturing technology. During high speed machining, a serrated chip is most often generated which affects nearly every aspect of high speed machining process, such as cutting force, cutting temperature, cutting tool wear and life and machined surface quality. Therefore, it is necessary to predict the formation of serrated chip and its relation with workpiece material and machining condition. Cutting heat and cutting temperature are the important research contents of high speed machining technology. The distribution and the change rule of the cutting temperature is one of the main basis of the process analysis in high speed machining. This research has important theoretical and practical significance. The temperature field in high speed cutting process are researched by means of FE modeling which can obtain temperature distribution on tool rake face and the influence of cutting parameters on cutting temperature that provides references for the investigation of tool wear mechanism and optimization of cutting parameters.In this dissertation, Johnson-Cook material model was used to simulate the chip morphology and cutting force as well as the temperature field distribution of AISI-1045 steel during high speed machining hardened steel in different rake angles using commercial FE software ABAQUS. A physical separation criterion is used to complete the separation of chip and workpiece, which a dynamic failure model is used in ABAQUS/Explicit to complete it. The effects of the rake angle on the chip morphology and cutting force were discussed. The simulation results were verified by experiment. The investigation indicates that the simulation results are consistent with the experiments. Serrated chip generated during high speed machining AISI-1045 hardened steel, and the sawtooth degree as well as pitch increases with decreasing tool rake angle when other conditions are fixed, so as cutting force. The study result of temperature field distribution during high speed machining hardened steel show that the tool tip region is not the highest temperature region, which in the region of a certain distance from tool tip. The simulation and experiment shows that the FE simulation method introduced in this dissertation can be use to predict the chip morphology and the cutting force as well as the temperature field distribution accurately during high speed machining hardened steel.