Finite element simulations of rail milling based on the modified Johnson-Cook constitutive model

Abstract

Abstract Rail milling plays an indispensable role to remove surface defects and irregularity in the railway maintenance industry. In this paper, an appropriate 2D orthogonal cutting model of rail milling process was established. Finite element simulations of rail milling were conducted in detail based on a modified Johnson-Cook constitutive model. The simulation results show that a large amount of cutting heat is generated in the tool-chip contact region, and the highest temperature of the milling insert appears somewhere on the rake face with a certain distance away from the cutting edge. With the increase of cutting thickness and milling speed, the milling temperature displays an upward trend.