Effect of cutting tool microgeometry when milling hardened steels, a finite element simulation and surface integrity analysis

Abstract

This research work presents a 3D finite element model for the milling of hardened steels. The model was developed using ABAQUS/Explicit software and the Lagrangian approach was utilized. Experimental milling tests were performed to validate the numerically generated cutting forces and chip morphologies. A close agreement between the results was reported. Moreover, experiments results were used to investigate the impact of cutting conditions and the microgeometry of cutting inserts on the cutting forces and the surface integrity. Two levels of feed rate, three levels of cutting speeds, and five levels of edge radii were utilized. The impact of edge radii on the workpiece surface integrity was analyzed in terms of 2D surface roughness, generated feed marks, subsurface plastic deformation, and subsurface microhardness.