3D-FEM Approach of AISI-52100 Hard Turning: Modelling of Cutting Forces and Cutting Condition Optimization

Abstract

In the present study, a 3D finite element (FE) model for machining AISI-52100 steel was proposed, with respect to three levels of cutting speed (100 m/min, 150 m/min and 200 m/min), feed (0.08 mm/rev, 0.11 mm/rev and 0.14 mm/rev), depth of cut (0.20 mm, 0.30 mm and 0.40 mm) and tool nose radius (0.80 mm, 1.20 mm and 1.60 mm). Nine simulation tests were performed according to cutting conditions that were used in experimental studies, in order to verify the accuracy of the model. Next, the FE model was utilized to carry out thirty new simulation runs, with cutting conditions derived from the implementation of the central composite design (CCD). Additionally, a mathematical model was established for prediction purposes, whereas the relationship between the applied cutting parameters and their influence on the resultant cutting force was investigated with the aid of statistical methodologies such as the response surface methodology (RSM) and the analysis of variance (ANOVA). The comparison between the numerical and the statistical model revealed an increased level of correlation, superseding 90% in many tests. Specifically, the relative error varied between −7.9% and 11.3%. Lastly, an optimization process was performed to find the optimal cutting conditions for minimizing the resultant machining force, as per the standardized tool nose radius value.