Influence of Material Models Used in Finite Element Modeling on Cutting Forces in Machining

Finite element modeling of machining is significantly influenced by various modeling input parameters such as boundary conditions, mesh size and distribution, as well as properties of workpiece and tool materials. The flow stress model of the workpiece material is the most critical input parameter. However, it is very difficult to obtain experimental values under the same conditions as in machining operations.. This paper analyses the influence of different material models for two steels (AISI 1045 and hardened AISI 52100) in finite element modelling of cutting forces. In this study, the machining process is scaled by a constant ratio of the variable depth of cut h and cutting edge radius r beta. The simulation results are compared with experimental measurements. This comparison illustrates some of the capabilities and limitations of FEM modelling.