Finite element modeling of machining with interactive friction model based evolutionary friction

This article presents the finite element modeling and simulation of machining with evolutionary friction, which was obtained from the interactive friction model (IFM). An empirical-numerical approach was used for IFM calibration, and the simulated annealing optimization was used to determine the IFM parameters. As the first step, the validated FEA simulations with constant friction coefficients were used to extract the interfacial parameters (i.e., pressure, sliding velocity, and temperature). Afterward, the interfacial parameters of the marginal nodes were fed into the IFM to optimize the model parameters. The evolution of the coefficient of friction obtained from the calibrated IFM was afterward used to generate the FEA model, which was validated with experimental cutting force. Finally, the performance of the IFM-based FEA model was compared with that of the constant friction coefficient. It was found that the inclusion of the evolution of friction with cutting time caused a shift in the FEA-simulation-based cutting force, feed force, thrust force, and temperature to move in the projected direction of friction. The adopted approach of IFM calibration can be helpful as an alternative to the friction data for machining interfaces, which are challenging to achieve through tribology tests. • Evolutionary friction instead of constant friction for FEA of machining. • Evolutionary friction from time-dependent interactive friction model. • Innovative approach for calibration and determination of model parameters. • FEA with evolutionary friction had a good agreement for the cutting forces. • Cutting force, temperature, stress, and strain justified FEA model efficacy.