Computation and experimental validation of the oblique cutting process in AL2024-T4 and AISI 4340

Oblique cutting is considered in this paper by implementing a numerical simulation model with ABAQUS/Explicit applied to two metallic materials, Al 2024-T4 and AISI 4340. An explicit algorithm for thermomechanically coupled problems is used. Two basic parts are considered: the workpiece and the cutting tool (a hard metal), this one being assumed also deformable. A thermoviscoplastic behavior is included for the workpiece by means of the Johnson-Cook law. An interface between the chip and machined workpiece is defined. Along this zone a cumulative damage failure criterion is applied and chip formation is brought about by the elimination of failing elements. Force components and temperature are analyzed in terms of different model parameters: the cutting velocity, the edge angle, the rake angle and the interface thickness. Several hollow cylinders have been turned for the results validation. Forces and temperature are measured by means of a piezoelectric platform and a thermographic camera, respectively. Force components in the cutting and normal direction fit well with numerical results. The effect of the cutting parameters in temperature variation is also in agreement with the numerical simulations.