A Coupled Eulerian Lagrangian Model to Predict Fundamental Process Variables and Wear Rate on Ferrite-pearlite Steels

Abstract

A coupled Eulerian-Lagrangian Finite Element model of the orthogonal cutting process was developed to predict the influence that ferritepearlite steel variants have on fundamental process variables and tool wear. As a case study, this paper is focused on two different ferritepearlite inclusion free alloys, where mainly the influence of ferrite-pearlite ratio was tested. Flow stress behavior based on dynamic compression tests and thermal properties function of temperature were characterized for model input parameters. The numerical model is compared with orthogonal cutting tests where the cutting and feed forces, tool temperature, chip morphology and tool wear related variables were measured. Globally, predicted tendencies match with experiments in forces and temperatures. Widest differences on predictions were found for chip thickness and tool-chip contact length. Predicted wear rates are in accordance to experimentally measured values.