Modelling of precision hard cutting using implicit finite element methods

In this paper the results of a numerical investigation dealing with finite element modelling of precision hard cutting of ball bearing 100Cr6 steel are presented. Based on the real turning chip cross-section, coming from the nominal values of tool nose radius, feed and depth of cut, an equivalent thermo-mechanical plane-strain orthogonal cutting model is constructed, with mean representative values of depth and width of cut, by employing the commercial FE code MARC. The effect of tool cutting edge radius, cutting speed and of various material constitutive models on the predicted stress and temperature fields, as well as the principal and thrust forces is discussed. Comparisons of predicted and experimentally measured quantities indicated a good agreement between cutting forces and temperatures but poor results in the case of thrust forces. The possible reasons as well as problems and uncertainties in FE cutting modelling are discussed.