Finite element modeling of hard turning process via a micro-textured tool

Literature survey showed that the micro-textures on the tool rake face can help in reduction in friction at chip-tool interface and therefore, reduction in the cutting forces. Consequently, the current work is based on FE simulation of hard turning of bearing steel (AISI52100). Four types of micro-textures have been considered on the tool rake face: non-texture, perpendicular, parallel, and rectangle. Johnson-Cook (J-C) material constitutive law has been considered for the workpiece with temperature-dependent material properties. Experimental work has been performed at cutting conditions: type, parallel; edge distance, 0.195 mm; pitch size, 0.110 mm; and height of the texture, 0.049 mm to validate the current machining model. Parametric study of effect of tool feature parameters on the cutting forces has been performed. Based on the current model, it is observed that the perpendicular shape showed the minimum cutting force. The maximum reduction of 28 % was predicted in the effective coefficient of friction compared to the non-textured surface. Additionally, effect of size of the texture (edge distance, pitch size, texture height) and the friction factor at tool-chip interface on the process responses is predicted. The perpendicular texture at an edge distance of 100 mu m, pitch size of 100 mu m, and texture height of 50 mu m showed the most effective shape and size for the minimum cutting forces and effective friction. It is simulated that the chip flow angle can be governed by the shape/size of the texture on the tool rake face. It is expected that the current model can further be helpful in the characterization of other hard materials and complex texture shape/size.