Identification of rheological parameters and numerical simulation for orthogonal machining of AISI 52100 hard steel

In this paper, we performed a priori identification of Johnson-Cook’s (J-C) law parameters for the AISI 52100 hard steel by using the true stress-strain curves with different temperatures and strain rates and a numerical simulation of tensile tests. Then, these rheological parameters are used, on the one hand, for the developed finite element (FE) model based on an arbitrary Lagrangian-Eulerian (ALE) approach and, on the other hand, for the modified analytic Oxley’s model. For numerical simulation of the chip flow, the ALE approach allows the absence of a damage criterion and element distortion. For analytic modeling, some corrections have been made to Oxley’s theory by using J-C law and by taking into account a non-uniform distribution of the stresses at the tool-chip interface. For the last, Coulomb’s model governs the friction. The simulation results of machining force and temperature are confronted to experimental data realized for the orthogonal cutting of AISI 52100 hard steel (62 HRC) with a KD120 grade CBN tool. For this purpose, the numerical and analytical results have good agreement with the experiments.