Inverse analysis procedure to determine flow stress and friction data for finite element modeling of machining

This paper describes an inverse procedure to determine the constitutive constants and the friction conditions in the machining processes using Finite Elements (FE) simulations. In general, the FE modeling of machining processes is an effective tool to analyze the materials machinability under different cutting conditions. However, the use of reliable rheological and friction models represents the basis of a correct numerical investigation. The presented inverse procedure was based on the numerical results obtained using a commercial FE code and was developed considering a specific optimization problem, in which the objective functions that have to be minimized is the experimental/numerical error. This problem was performed by a routine developed in a commercial optimization software. In order to verify the goodness and the robustness of the methodology, it was applied on a Super Duplex Stainless Steel (SDSS) and on an Austenitic Stainless Steel (AUSS) orthogonal machining processes. This work, then, was focused on the identification of the Johnson-Cook (JC) coefficients (A,B,C, n and m) and on the calibration of a Coulomb friction model, in the specific cases of the SAF2507 SDSS and of an AISI 316 Based AUSS Alloy (AISI 316 ASBA). The identification phases were performed considering forces and temperatures experimental data, collected in two specific experimental tasks in which different orthogonal cutting tests were carried out under different cutting parameters conditions.