THERMO-MECHANICAL BEHAVIOR IN THE MICROMACHINING OF THE AISI 4140: NUMERICAL SIMULATION WITH EXPERIMENTAL VALIDATION

Abstract

In the last decade, various researches has shown how the finite element software can be used to predict the chip formation, cutting forces, temperature, tool wear, residual stresses in workpiece and other important parameters in machining. This article presents simulation using FEM (Finite Element Method) with experimental validation in orthogonal microturning of AISI 4140 steel. Machining simulation using FEM AdvantEdge® were applied to predict the cutting and thrust forces, von Mises stress, maximum cutting stress, plastic deformation, deformation rate and cutting temperature distribution. The work aims to evaluate the evolution of these variables as a function of feed rate using uncoated carbide tools. The orthogonal cutting was validated by comparing the cutting forces obtained experimentally with simulated results. Predictions of cutting temperature, plastic deformation and deformation rate during the machining of AISI 4140 steel were also obtained. The combination of finite element technique with actual measurements of cutting test allows to improve and to optimize the machining conditions. Experimental and simulated results showed close values as regards the cutting force. Keywords: AISI 4140; Finite Element Method; Machining simulation; Cutting temperature; Micromachining.