Evaluation of an Analytical Model in the Prediction of Machining Temperature of AISI 1045 Steel and AISI 4340 Steel

Abstract

This paper evaluates a physics-based analytical model in the prediction of machining temperature of AISI 1045 steel and AISI 4340 steel. The prediction model was developed based on the Johnson-Cook constitutive model (J-C model) and mechanics of the orthogonal cutting process. The average temperatures at two shear zones were predicted by minimizing the difference between calculated stresses using the J-C model and calculated stresses using the mechanics model. In this work, (1) the influence of input Johnson-Cook model constants, cutting force, and chip thickness on the accuracy of predictions are investigated with sensitivity analyses, in which multiple sets of available J-C constants and varying cutting force and chip thickness are used for the temperature prediction in machining AISI 1045 steel. The larger the input deviation, the larger prediction deviation. The temperature at the primary shear zone is more susceptible to the deviation of inputs than the temperature at the secondary shear zone. (2) The machining temperatures are also predicted in machining AISI 4340 steel using cutting tools with various specifications to demonstrate its predictive capability. Good agreements are observed upon validation to available experimental data in the literature. (3) Lastly, the advantage and limitation of the temperature model are discussed with comparison other analytical temperature models. Considering the reliable and easily measurable input requirements and sufficient predictive capability, this temperature model can be employed for effective and efficient machining temperature prediction.