Improved prediction of cutting forces via finite element simulations using novel heavy-load, high-temperature tribometer friction data

Prediction of forces in cutting operations is a valuable asset to manufacturers. This paper demonstrates the improvements in force prediction achievable in finite element simulations of orthogonal cutting with the incorporation of temperature-dependent friction data obtained from a custom heavy-load, high-temperature tribometer. The tribometer employed is briefly described and its similarities to tool-chip contact in cutting discussed. Simulations with the temperature-dependent friction data were performed over a range of uncut chip thickness, cutting speed, and tool flank wear conditions. For comparison sake, select simulations were also run using a constant friction coefficient model and all simulation results were validated against experimentally obtained force measurements. The temperature-dependent friction data simulations capture the experimental trends in force with respect to all three of the parameters investigated. For unworn tools, the simulations tend to slightly overestimate the tangential and feed force components. For worn tool profiles, the simulations predicted forces with minimal error for most scenarios, overestimating the tangential force and underestimating the feed force. Comparison of simulated temperatures with the range of those for which experimental material properties were obtained, particularly friction coefficients, is proposed as a useful check as to whether simulation results can be reasonably trusted.