Similarity considerations on the simulation of turning processes of steels

In order to investigate size effects occurring in the miniaturization of turning processes a complete dimensional analysis using a materials model for high-speed deformation was performed. The derived dimensionless similarity numbers were used to guide the parameter variation in simplified two-dimensional finite-element simulations for orthogonal cutting. The rate-dependent material model leads to size effects like an increase of the specific cutting force while reducing the cutting depth. A counter-intuitive dependence of the cutting force on cutting velocity is explained using a shear-plane model. The derived dependencies on single input parameters are used to predict output values while simultaneously changing several input parameters.