International Scientific Journals
of Scientific Technical Union of Mechanical Engineering "Industry 4.0"

High-speed machining (HSM) significantly influences the thermal dynamics of the cutting process, particularly in the toolworkpiece interaction zone. At elevated cutting speeds, the reduced tool-workpiece contact time minimizes heat transfer to the workpiece, concentrating thermal energy in the cutting zone. This results in localized material softening, reduced cutting forces, and enhanced process efficiency. This study investigates the thermal effects of HSM by experimentally turning C45 steel using a cubic boron nitride (CBN) tool at cutting speeds ranging from 800 m/min to 1800 m/min. Cutting forces were measured and analyzed in conjunction with temperature distributions within the cutting zone and tool. The experimental results were compared against predictions from the analytical Oxley machining model and numerical simulations using DEFORM software. The analysis revealed the dependence of cutting speed on cutting zone thermal properties, providing insights into material behavior under high-speed conditions. Furthermore, the study identified optimal cutting speeds that balance thermal effects and cutting process stability. These findings contribute to the definition of appropriate high-speed machining parameters, ensuring effective heat dissipation and stable tool performance.

This study presents the development of a Finite Element Method (FEM) model to simulate cutting processes, focusing on the analysis of various parameters such as stress, strain, temperature, and cutting forces in the cutting zone. The FEM model is developed using Mentat software and solved with the Marc solver. By employing this method, we can effectively manage cutting parameters, optimize cutting tool geometry, predict tool wear, and improve tool life. The research investigates key parameters and their values, providing insights into the cutting process that can enhance efficiency and performance. The application of FEM in this context offers a robust framework for advancing the understanding and development of cutting technologies. Various software applications that support these investigations are also explored, underscoring the versatility and precision of FEM in cutting process simulations.

Modeling and simulating cutting processes play a pivotal role in the advancement of machining manufacturing. This enables machining design technologists to scrutinize and optimize intricate machining processes before their implementation in manufacturing. The Finite Element Method (FEM) emerges as a robust numerical technique widely employed for simulating cutting processes in manufacturing. While FEM proves particularly well-suited for cutting simulation, it is imperative to make judicious choices regarding the FEM method and software for effective implementation in cutting simulations.
The realm of FEM software is diverse, encompassing various analysis options such as mechanical, thermodynamic, and contact analyses. However, the selection of appropriate FEM software is not only contingent upon these analysis options but also influenced by factors like the user interface and the requisite understanding of the physical nature inherent in the modeled cutting process.
In the scope of this study, a simplistic orthogonal cutting model is formulated utilizing the FEM software DEFORM and the FEM software MARC MENTAT. The attained results are meticulously evaluated by comparing them not only in relation to practical applicability but also considering the challenges and intuitiveness associated with the creation of a machining model.