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In the current work, the main goal is to make a
prediction of the influence of the friction coefficient when
machining an AISI 1045 steel. An experimental validation of the
process was also conducted in order to meet the results found when
machining the steel with commercial finite element software. The
comparison shows that the friction modeling at the tool-chip
interface has a significant influence in the final results.
Additional studies could also be obtained from the simulation like
cutting forces, temperature, plastic strain and plastic strain rate.
Therefore, the objective of this work is to address the friction
value in the tool-chip interface and its influence in the simulated
results. From the simulations and experimental work (in orthogonal
cut), it can be concluded that the friction coefficient is crucial
to obtain valuable predictions when machining with the FEM model.
Figure 1: Simulated forces and temperature for
the orthogonal cut of AISI 1045 along the depth of cut. Cutting
speed was 100 m/min with a feed of 0.1 mm/rev and a depth of cut of
2.5 mm
Figure 2: Comparison between experimentation and
simulation (with a friction coefficient of 0.44) for the cutting
temperature for the orthogonal cut of AISI 1045. The cutting speed
was 100 m/min with a feed of 0.1 mm/rev and a depth of cut of 2.5 mm
Figure 3: Temperature distribution at the end of
the length of cut in the tool, workpiece, chip and burr
Figure 4: Comparison between experimentation and
simulation (with a friction coefficient of 0.44) for the plastic
strain for the orthogonal cut of AISI 1045. The cutting speed was
100 m/min with a feed of 0.1 mm/rev and a depth of cut of 2.5 mm
Figure 5: Plastic strain distribution at the end
of the length of cut in the tool, workpiece, chip and burr
Figure 6: Plastic strain rate distribution at the
end of the length of cut in the tool, workpiece, chip and burr |