PSI - Issue 53

13

A. Teixeira et al. / Procedia Structural Integrity 53 (2024) 352–366 Author name / Structural Integrity Procedia 00 (2019) 000–000

364

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Fig. 18. Cutting loads for turning simulation at: (a) f=0.1 mm/rev and (b) f=0.2 mm/rev.

When comparing the simulated cutting force values with the experimental ones, seen in Fig. 19, at f=0.1 mm/rev an average relative error of 3% was obtained. Except for v c =50 m/min, when the error was 57%, an error of 1% at f=0.2 mm/rev was obtained. These differences in values can be explained by the fact that, at v c =50 m/min and f=0.2 mm/rev, the cutting tool suffered high wear which had an impact on the cutting forces, as seen before. This wear is not accounted for in the simulation, as such, causing this difference in force values. Apart from that, the numerical model showed a good correlation between the cutting forces, being able to predict them with accuracy and taking into consideration the effects of thermal softening and/or strain rate hardening.

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Fig. 19. Comparison between experimental and simulated values of F c at: (a) f=0.1 mm/rev and (b) f=0.2 mm/rev.

Figs. 20 and 21 shows the similarities between the experimental and simulated wear at a cutting speed of 150 m/min and feeds of 0.1 and 0.2 mm/rev, respectively. Although the present model does not consider tool flank wear, the tool workpiece interface at the rake face appears to be properly reproduced. The morphology of the wear zone is consistent with the wear zone produced during experimental test, even predicting wear on the chip breaker.

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Fig. 20. Wear on the rake face at v c =150 m/min and f=0.1 mm/rev: (a) experimental and (b) simulation.