Relationship between cutting process parameters and white layer thickness in orthogonal cutting

In this paper, a 2D orthogonal cutting of hardened AISI52100 steel is developed to investigate the influence of cutting process parameters (CPP) on white layer (WL) thickness. A finite element model (FEM) based on the phase transformation mechanism and takes into account the mechanical effects is adopted to predict the WL depth. Several numerical simulations are performed in various conditions of tool geometry, tool flank wear, material properties, and cutting conditions. The predicted results of cutting forces, chip morphologies, and WL depth are physically consistent with the previous experimental investigations. The numerical results prove that formation of thick WLs is unavoidable in all cases, except for low workpiece hardness, very thin WLs are noticed. The results also confirm that the WL thickness depends on all used CPP. In particular, the cutting speed, feed, tool flank wear, and workpiece hardness are the most influencing parameters.