Development of 2D-Machining Test for Assessing Material Properties in Metal Cutting

In Swedish automotive industry, metal cutting operations are extremely important processes for production of high performance advanced components. To cope with future demands on efficient machining it is important to model/simulate the machining process to be able to design the machining process without or with minimum amount of pre-tests. Another goal is to have safe and robust production processes involving new materials in the manufacturing. This places high demands on the development of the consequent modeling and simulation strategy with respect to proper handling of the new materials and the adequate simulation results. In order to simulate the metal cutting processes, it is necessary to apply an appropriate model to describe the material response at high strain rates and high temperatures. On the other hand, unlike the other forming processes, deformation rate in metal cutting processes is often extremely high in cutting zone, and therefore are far beyond the attainable ranges in conventional tensile testing instruments. One way to obtain the mechanical properties at such severe conditions is to use inverse modeling of orthogonal cutting. In this method, often, the results of an analytical model are compared with corresponding experimental results, and once the difference between them is less than an error tolerance, the material inputs for the model are taken as the optimum material parameters. In this project, the focus is put on determination of the material parameters of a modified Johnson-Cook model for AISI 1080 fully pearlitic steel having two different heat treatments