The aim of the present paper is to study by Finite Element Method (FEM) the hard turning of 42CrMoS4 steel. A numerical and experimental study was carried out to analyze the effect that cutting parameters have on cutting and feed forces, temperatures on the cutting zone, contact length and chip morphology. A flow stress model for the FEM model was developed by dynamic compression tests. Experimental tests were done to establish the accuracy of the FEM model, developed in DEFORM. The tendencies of both frameworks agreed in forces and temperatures. Greater differences were found for contact length and chip thickness predictions.
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