ABSTRACT
Dry hard turning, an environmentally friendly process, has many benefits over cutting-fluid-based hard-turning operations. The environmental impact in dry hard turning is positive as unhealthy cutting fluids are ignored. The model created is an idealization of the real physical system and with proper modeling, it yields accurate solutions. The main objectives of using finite element (FE) models are optimizing the material removal process by increasing tool life and by producing better surface integrity. In the present study, the hard-turning operation of the AISI 4340 workpiece is modeled using finite element method while subjected to given loads or boundary conditions to accurately determine the responses. The model created is an idealization of the real physical system to yield accurate solutions. This advancement in technology helps in fast creation, analyzing, and producing products to satisfy demands. It is difficult to obtain output responses at the deformation zone through practical experiments. In the present work, the cutting force and shear angle for the orthogonal cutting of AISI 4340 steel with Al2O3-coated tungsten-based cemented carbide cutting inserts are predicted for different cutting speeds with a fixed feed rate and depth of cut. Furthermore, the predicted value of forces is validated with an experimental value. For the simulation purpose, ABAQUS® finite element–based package is used. To study the plastic deformations that occur in the workpiece, Johnson–Cook material model is used.
