Sensitivity analysis of the constitutive models in FEM-based simulation of the cutting process

The paper considers the problem of the influence of constitutive model parameters on the results of FEM-based simulation of the orthogonal cutting process using C45 (AISI 1045) carbon steel and multilayer-coated carbide tool. The simulations were based on the power constitutive law (PL) with a special consideration of the temperature-related thermal influences. The sensitivity analysis performed concerns the models proposed by Özel and Kalhori and own data in the form of multi-regressive equations for the substrate and coating components that were applied. In particular, the values of n exponent were varied in order to assess the simulation results. The FEM simulations include the average interface temperature, the distribution of temperature on the rake face and within the wedge body, as well as cutting forces. By modifying the PL parameters, the prediction errors lower than 15% were obtained.