Experimental Based Chip Formation Simulation for Cold Work Steel AISI D2

Chip formation simulations provide an effective tool for the further development of machining processes. The models on which the simulations are based require a realistic prediction of the flow stress behavior of the material as well as the friction behavior of tool and material. In the presented work, experimental investigations were carried out to characterize the flow stress and friction behavior for the machining of the cold work steel AISI D2 and the resulting models have been implemented in finite element chip formation simulations. These simulations are validated concerning mechanical loads using orthogonal cutting experiments.