ORIGINAL ARTICLE On the finite element modelling of high speed hard turning A. G. Mamalis & J. Kundrák & A. Markopoulos & D. E. Manolakos Received: 7 November 2006 / Accepted: 25 May 2007 / Published online: 14 August 2007 # Springer-Verlag London Limited 2007 Abstract The results reported in this paper pertain to the simulation of high speed hard turning when using the finite element method. In recent years high speed hard turning has emerged as a very advantageous machining process for cutting hardened steels. Among the advantages of this modern turning operation are final product quality, reduced machining time, lower cost and environmentally friendly characteristics. For the finite element modelling a commer- cial programme, namely the Third Wave Systems Advant- Edge, was used. This programme is specially designed for simulating cutting operations, offering to the user many designing and analysis tools. In the present analysis orthogonal cutting models are proposed, taking several processing parameters into account; the models are validat- ed with experimental results from the relevant literature and discussed. Additionally, oblique cutting models of high speed hard turning are constructed and discussed. From the reported results useful conclusions may be drawn and it can be stated that the proposed models can be used for industrial application. Keywords Machining . Finite element method . Hard turning 1 Introduction Hard turning, a machining operation used for the process- ing of hard materials such as hardened steels, has been brought into the forefront of modern metal cutting operations with the increasing demand for manufacturing high quality components, e.g., gears, shafts, bearings, dies and tools, from these kinds of materials. Cutting tools employed in hard turning are made of specialized tool materials, such as cubic boron nitrite (CBN), that are able to overcome the problems experienced during the process [1]. These cutting tools are ideal for machining iron-based materials at the severe cutting conditions associated with hard turning; they possess exquisite properties, even at elevated temperatures, allowing for their application at high cutting speeds and without the use of any cutting fluids [2]; by dry cutting not only environmentally-friendly character- istics are attributed to the process, but also cost reduction can be attained by omitting buying and disposal costs of the cutting fluids [3–5]. In addition the combination of hard turning and high speed machining is proved to be very advantageous since a great reduction in processing time can be achieved [1]. Hard turning is very advantageous for a wide spectrum of applications and is also considered as an alternative for a variety of processes, since the single-step superfinish hard turning can replace the abrasive processes, traditionally used as finishing operations, or non-traditional processes, such as electrical discharge machining (EDM), in machin- ing hard parts, offering accuracy equal to or better than that provided so far, flexibility and considerable machining time and cost reduction [4–7]. Note, however, that hard turning has not been introduced into modern industry as much as it should be, mainly because of phenomena such as rapid tool wear or cracking Int J Adv Manuf Technol (2008) 38:441–446 DOI 10.1007/s00170-007-1114-9 A. G. Mamalis (*) : A. Markopoulos : D. E. Manolakos Manufacturing Technology Division, National Technical University of Athens, Athens, Greece e-mail: mamalis@central.ntua.gr J. Kundrák Department of Production Engineering, University of Miskolc, Miskolc, Hungary