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<p>An accurate cutting simulation model is crucial for understanding the cutting process, designing tools, and optimizing cutting parameters. In this study, an accurate cutting simulation model is developed, in which the constitutive model, the thermophysical properties model, and the friction model are used. First, constitutive models for the workpiece material were established based on experimental data obtained from split Hopkinson pressure bar (SHPB) experiments at different high strain rates and high-temperature hardness experiments conducted within the temperature range of 25–800&#xa0;°C. A thermophysical properties model and a friction model were established based on experimental data obtained from laser-flash analysis (LFA) experiments conducted at temperatures ranging from 25 to 1000&#xa0;°C and orthogonal cutting experiments conducted at cutting speeds of 50–250&#xa0;m/min with feed rates of 0.05–0.20&#xa0;mm/rev, respectively. Subsequently, A simulation model considering the residual stress from cutting was established. To verify the accuracy of this model, orthogonal cutting experiments with different cutting speeds and feed rates were conducted. The simulation ignoring residual stress shows significant differences, with an average error of 29.25%. In contrast, the consistency between the simulation considering residual stress and the experiment is significantly improved, with an average relative error of 9.53%, which is within an acceptable engineering range. This indicates that the established simulation model can accurately and reliably predict the cutting behavior of 42CrMo steel.</p>

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The development of turning simulation model with the cutting induced hardening for 42CrMo steel

  • 期刊论文

  • 发表日期：

    2026年7月31日

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  • Tao Zhang,
  • Qishi Fang,
  • Hui Dong,
  • Shizhan Huang,
  • Jiaming Liu,
  • Zekai Huang,
  • Hongfei Yao,
  • Xuming Zha,
  • Feng Jiang,
  • Qianting Wang

摘要

An accurate cutting simulation model is crucial for understanding the cutting process, designing tools, and optimizing cutting parameters. In this study, an accurate cutting simulation model is developed, in which the constitutive model, the thermophysical properties model, and the friction model are used. First, constitutive models for the workpiece material were established based on experimental data obtained from split Hopkinson pressure bar (SHPB) experiments at different high strain rates and high-temperature hardness experiments conducted within the temperature range of 25–800 °C. A thermophysical properties model and a friction model were established based on experimental data obtained from laser-flash analysis (LFA) experiments conducted at temperatures ranging from 25 to 1000 °C and orthogonal cutting experiments conducted at cutting speeds of 50–250 m/min with feed rates of 0.05–0.20 mm/rev, respectively. Subsequently, A simulation model considering the residual stress from cutting was established. To verify the accuracy of this model, orthogonal cutting experiments with different cutting speeds and feed rates were conducted. The simulation ignoring residual stress shows significant differences, with an average error of 29.25%. In contrast, the consistency between the simulation considering residual stress and the experiment is significantly improved, with an average relative error of 9.53%, which is within an acceptable engineering range. This indicates that the established simulation model can accurately and reliably predict the cutting behavior of 42CrMo steel.