Engineering Transactions, 60, 2, pp. 113–124, 2012

Modelling the Peak Cutting Temperature During High-Speed Machining of AISI 1045 Steel

Timothy J. BURNS
National Institute of Standards and Technology Information Technology Laboratory

Steven P. MATES
National Institute of Standards and Technology Material Measurement Laboratory

Richard L. RHORER
National Institute of Standards and Technology Engineering Laboratory

Eric P. WHITENTON
National Institute of Standards and Technology Engineering Laboratory

Debasis BASAK
Orbital Sciences Corporation

This paper presents new experimental data on AISI 1045 steel from the NIST pulse-heated
Kolsky Bar Laboratory. The material is shown to exhibit a stiffer response to compressive
loading when it has been rapidly preheated, than it does when it has been heated using
a slower preheating method, to a testing temperature that is below the eutectoid temperature.
It is argued, using a simple model for heat generation in the workpiece and the tool during
machining, due to Tlusty, that this work has important implications for the modelling of high-
speed machining operations. Based on the experimental data, a modification is recommended of
the well-known Johnson-Cook constitutive model of Jaspers and Dautzenberg for this material,
in order to achieve improved predictions of the peak cutting temperature in machining.
Keywords: high-speed machining, thermal modelling, AISI 1045 steel, Kolsky bar
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