Analysis of hard turning process:thermal aspects

In manufacturing sector,hard turning has emerged as a vital machining process for cutting hardened steels.Besides many advantages of hard turning operations,one has to implement to achieve close tolerances in terms of surface finish,high product quality,reduced machining time,low operating cost and environmental friendly characteristics.In the study,three dimensional(3D) computer aided engineering(CAE) based simulation of hard turning by using commercial software DEFORM 3D has been compared to the experimental results of stresses,temperatures and tool forces in machining of AISI D3 and AISI H13 steel using mixed ceramic inserts(CC6050).In the following analysis,orthogonal cutting models are proposed,considering several processing parameters such as cutting speed,feed and depth of cut.An exhaustive friction modelling at the tool-work interface is carried out.Work material flow around the cutting edge is carefully modelled with adaptive re-meshing simulation capability of DEFORM 3D.The process simulations are performed at constant feed rate(0.075 mm/r) and cutting speed(155 m/min),and analysis is focused on stresses,forces and temperatures generated during the process of machining.Close agreement is observed between the CAE simulation and experimental values.