Evaluation of Chip Morphology in Hard Turning Using Constitutive Models and Material Property Data

Modeling of machining operations requires the use of constitutive relations which could represent as close as possible the material behavior in the primary and secondary zones. The knowledge of these behavior laws involves the use of different types of sophisticated mechanical tests which should provide with sufficient accuracy the material behavior for the relevant conditions of machining. In this paper, first, the flow stress of 100Cr6 (AISI 52100) bearing steel in its HV730 hardness state has been identified in order to assess the machinability in case of hard turning. With this, the dependence of the flow stress on strain, strain rate and temperature, which poses significant difficulty, is presented. Second, the material machinability is evaluated with a shear instability criterion, enabling the prediction of chip formation with or without the shear localization. Quick-stop tests have been carried out on the bearing steel treated at different hardness values showing the chip formation variation. Micro-hardness tests performed on these quick-stop test samples show the effects of cutting temperature. A greater understanding of applied machinability is gained through this precise study of work material physical properties and behavior.