(Dr. Tom Kurfess, advisor)
"A Numerical Simulation of Hard Turning 52100 Steel to Detect White Layer Formation"
In order to replace finish grinding operations by hard turning, a better understanding of the behavior of hard materials needs to be achieved; including heat generations, subsurface damage, and surface integrity.
Hard turning refers to cutting materials approximately 45 HRC and higher. Hardened steels are widely used in applications where good materials mechanical characteristics are required. These parts are traditionally machined by fine grinding to obtain the tight specifications.
The goal of this thesis is to create a simplified FEM model of hard turning with the greatest range of applicability possible. The proposed simulation models the temperatures and the stresses that occur during the machining process. Such a model would be of great value in reducing the number of trial-and-error experiments that traditionally are used for tool design, process selection and machinability evaluation. The simplified model developed is designed to optimize cutting conditions for hard turining in order to be able to produce the desired finish.
Such an understanding may help to economically justify the hard turning
as an alternative to traditional finishing processes.