Finite Element Modelling of Temperature in Machining of Duplex Stainless Steel (DSS) 2205

Abstract

Duplex stainless steels (DSSs) are a group of austenitic - ferritic stainless steels featuring an excellent resistance to corrosion and mechanical strength, which makes them the most suitable material to be used in highly corrosive environments. The superior chemical and mechanical properties of DSSs are a result of excessive alloying which renders them very poor machinability. Low machinability combined with high hardness of DSSs generate high temperatures during machining. Exposure to elevated temperatures induces embrittlement, the formation of unwanted intermetallic precipitates and microstructural changes. The high amount of heat generated also shortens the tool life, leads to higher surface roughness and dimensional sensitivity. Hence it is important to study the temperature distribution generated during machining of DSS. In this work, Finite Element modelling and simulation (ABAQUS) for orthogonal and oblique cutting of DSS 2205 was developed using explicit temperature dynamic analysis and meshing was based on Lagrangian formulation. Johnson-Cook material model has been utilized for defining flow stress of the work material. The model developed was validated by experiments conducted using coated WC cutting inserts and the temperatures were measured using thermal camera and thermocouple setup. It was found that the simulated values were able to follow the pattern of the experimental results. The change in temperature distribution due to the coating on the tool was studied.