The Influence of Tool Flank Wear and Depth of Cut on Temperature Fields Based on Johnson-Cook Model in Dry Hard Machining

Temperature is considered to be one of the most important aspects to take into account in dry hard machining. However, dry hard machining is a complex process, and the temperature is the most difficult to be measured when machining. Up to now, only very few studies have been reported on influence of tool wear and depth of cut on temperature fields produced during dry hard machining AISI D2 steel in its hardened state (60-62HRC). In this paper, ALE formulation with techniques such as adaptive meshing, which effectively avoided difficulty of chip formation when using Eulerian formulations, was utilized to propose finite element model based on the well known Johnson--Cook model and the Brozzo´s facture criteria. This finite element mode was properly calibrated by means of an iterative procedure based on the comparison between experimental results from literatures and numerical data. At last, this finite element mode was utilized to predict influence of tool wear and depth of cut on temperature fields and applicability of the adiabatic conditions at dry hard machining hardened D2 steel. From this study, it was also possible to properly analyze the influence of tool wear and depth of cut on the temperature fields for industrial application.