Thermo mechanical modeling of turning process using an Arbitrary Lagrangian-Eulerian method

In this paper, thermo mechanical simulation of turning process has been developed using commercially available finite element analysis software, ABAQUS. A 2-D orthogonal cutting has been modeled using an Arbitrary Lagrangian-Eulerian (ALE) formulation. The Johnson-Cook plasticity model has been assumed to describe the material behavior during the process. Adaptive meshing dynamic explicit is also employed in this model to avoid the severe deformation. This study is aimed at temperature and stresses distributions during machining of AISI 1045 steel with three different rake angles; α=+10°, 0° and -10° and tool edge radius, p = 0.1mm, 0.5mm and 0.7mm. The results showed that the maximum stress for +10°, 0° and -10° are 1060MPa, 1040MPa and 1070MPa while the maximum temperature results shown that 835 °C, 893°C and 914°C. The maximum stress and temperature of tool edge radius also have been captured.