Reproducibility analysis for different numerical models and experimental setups in dry orthogonal cutting of AISI 4140 steel

The design of machining processes still requires iterative parameter optimisation on the real process to achieve the demanded quality. In order to use simulation results as input for models of lubricated machining processes, which is the final aim of the presented work, it is necessary to assure that already the chip forming simulations under dry conditions produce valid results. Due to extreme conditions in the chip formation zone, including high contact stresses, temperatures and deformations, advanced requirements are imposed on a numerical model. In this work, orthogonal turning of AISI 4140 steel is simulated and experimentally investigated. Aiming for a critical examination of the conventional practice to validate simulation results only through a single experimental setup, the experiments are carried out redundantly on three varying turning lathes and measurement systems. Numerical simulations are performed using finite element analysis (FEA) within the software packages ABAQUS, AdvantEdge, DEFORM and Marc, as well as meshfree methods in the form of the finite pointset method (FPM) within MESHFREE and an element-free Galerkin method (EFG) in LS-DYNA. The obtained results demonstrate the characteristics of the individual simulation methods as well as the degree of reproducibility in experiments.