Cutting force

and tool temperature

Fundamentals of Mechanical Manufacturing

Teacher Hu Teng

Team of four, including Md Mithun

Machining

Finite element analysis

Johnson-Cook

Audit

We took a published finite element study of high-speed cutting of AISI 4340 steel, reproduced its logic and audited it. I checked the numbers against Merchant theory and handbook data.

0 to 20°

of rake angle studied

300, 433, 550

cutting speeds in m/min

20 to 28%

lower cutting force as the rake angle rises

What

I did

Read the ABAQUS/Explicit Johnson-Cook study line by line.

Compared its trends with Merchant theory.

Checked its input values against handbook data.

Redrew its force and temperature plots so they can be compared at a glance.

+ Honest result

Where it fell short

I found input values that disagree with handbook data, and statements that do not match the plotted curves. I report both in the audit. The plots on this page are my redrawing of values I read off the source study's figures, so they carry a reading uncertainty of about 30 N and 10 degrees Celsius.

Plot of cutting force against rake angle

Plot of tool temperature against rake angle

Plots of force and temperature against rake angle

Force and tool temperature against rake angle at 300, 433 and 550 m/min. Values come from a published model (Sulaiman, Roshan and Ariffin, 2013), redrawn by me from the source plots, with a reading uncertainty of about 30 N and 10 degrees Celsius. I did not measure them. The source range is 10 to 18 degrees, and the working point of 14 degrees at 433 m/min sits near 900 N and 565 degrees Celsius.