Experimental investigation and 3D simulation of reaming process on AISI D2 hardened tool steel

In this study, 3D 8inite element simulation of reaming process has been carried out on the hard steel. The cutting parameters in the simulation process were selected based on the optimum experimental results which lead to the smaller cutting forces, lower vibration of the reaming tool and better surface quality. This simulation was used to predict cutting forces as one of the most important reaming output variables. Simulation of material removal process was performed by commercial finite element software SFTC DEFORM-3D and using the explicit Lagrangian code. In addition, some empirical experiments were done on the hardened D2 tool steel workpieces to 8ind the optimum reaming condition and validation of finite element model. Cutting parameters including feed rate and cutting speed were changed and cutting forces were measured, experimentally. The results showed that the numerical results have a good consistency with the experimental one and average difference of 10% was seen. Finally, the effect of input parameters on the cutting force at the simulation and experimental test were investigated. It was seen that the cutting forces error is reduced between two analyses by increasing the feed rate. This indicates that the meshes with higher quality and density are required in lower removal rate.