Numerical modeling of the influence of process parameters and workpiece hardness on white layer formation in AISI 52100 steel

White layer formation is considered to be one of the most important aspects to take into account in hard machining. Therefore, a large number of experimental investigations have been carried out in recent times on the formation mechanisms and properties of the white layer. However, up to now, only very few studies have been reported on modeling of the white layer formation. This paper presents a finite element model which predicts the white layer formation during machining of hardened AISI 52100 steel. This numerical model was properly calibrated by means of an iterative procedure based on the comparison between experimental and numerical data. The empirical model was also validated for a range of cutting speeds, uncut chip thickness, and material hardness values. This study provides excellent results concerning cutting force, temperature, chip morphology, and white layer. From this study, it was also possible to properly analyze the influence of process variables on the white layer formation.