Real 3D turning simulation of materials with cylindrical shapes using ABAQUS/Explicit

In this study, cutting forces and chip shapes formed by turning cylindrical materials were researched experimentally and numerically. AISI 4340 steel alloy with a hardness of about 30 Rockwell C scale was chosen as workpiece material. Most of the turning simulations performed by finite element method (FEM) have been conducted 2D (two-dimensional) because 3D (three-dimensional) is very difficult and time-consuming and mechanics of more complex 3D cutting operations are usually evaluated by using geometrical and kinematic transformation models applied to the 2D cutting Process. In other words, the workpiece was modeled as a flat specimen. Nevertheless, 3D (three-dimensional) simulation using cylindrical models are more nearer to practical process. For this reason, to get the actual cutting process, this paper aims to present a real 3D (three-dimensional) turning simulation model using ABAQUS/ Explicit software using tube and bar specimens with a cylindrical shape. Cutting forces were measured utilizing the Kistler 9129AA model piezoelectric dynamometer. Cutting forces and chip shapes obtained by making FEM simulations were compared. Simulation results were determined to be in high proximity with experimental results. Also, realistic chip shapes were simulated by FEM. Therefore, this method could be used as reliable in the industry.