Experimental and numerical investigation of cutting forces during turning of cylindrical AISI 4340 steel specimens

Abstract Cutting forces play a significant role in machining because they directly affect the mechanics of machining, the energy requirements, and the tool stability required. In this study, the cutting forces occurring during the turning of AISI 4340 material with 30 Rockwell C hardness scale have been analyzed both experimentally and numerically. Many types of research have been conducted via 2-D simulation using the finite element analysis method. In other words, in most studies, the workpiece was modeled as a flat specimen. Therefore, this paper presents a real 3-D turning simulation model using cylindrical specimens. The cutting forces were measured using a Kistler 9129AA model piezoelectric dynamometer. The ABAQUS/Explicit finite element method was used, and a model by Johnson and Cook was assigned as a material model in the numerical analysis. A new PVD AlTiN coated carbide insert was incorporated to prevent wear. Experimental results obtained from cutting tests were compared with numerical results to establish the accuracy of the FEM. It was observed that experimental and numerical results overlapped each other. Thus, this method can be used directly in the industry to reduce high processing costs.