Numerical analysis and experimental investigation in the machining of AISI 316 steel

High corrosion resistance and mechanical properties of AISI 316 stainless steel make its wide application in the nuclear power station and structural components in chemical industries. On the contrary, low thermal conductivity and high strain rate create problems during the machining of AISI 316, resulting in high cutting force and tool wear. Hence, this study investigates the thermal and mechanical behavior of AISI 316 steel during turning using a carbide tool. It is carried out in two stages: Finite element modeling (FEM) and experimental work. In the first stage, FEM is simulated using DEFORM software to study cutting forces, tool temperature, and chip morphology at different cutting speeds and feed rates. The results show that cutting speed and feed rate significantly affect the cutting force, thrust force and chip morphology. The chip morphology characteristics such as the degree of segmentation and serration frequency are studied. In the second stage, experimental trials are performed using the same input parameters to validate the simulated results. Results show a 10% error between simulated and experimental findings.