Numerical analysis of constitutive coefficients effects on FE simulation of the 2D orthogonal cutting process: application to the Ti6Al4V

In this paper, a deep study of constitutive parameters definition effect is done in order to guarantee sufficient reliability of the finite element machining modeling. The case of a particular biphasic titanium alloy Ti6Al4V known by its low machinability is investigated. The Johnson-Cook (JC) elasto-thermo-visco-plastic-damage model combined with the energy-based ductile fracture criteria is used. Segmentation frequency, chip curvature radius, shear band spacing, chip serration sensitivity and intensity, accumulated plastic strain in the formed chip segments, and cutting forces levels are determined where their dependency to every constitutive coefficient is examined and highlighted. It is demonstrated from the separate variation of every plastic and damage parameters that an interesting finite element modeling (FEM) relevance is reached with the adjustment of JC strain hardening coefficients term, thermal softening parameter, exponent fracture factor, and damage evolution energy. Moderate and high cutting speeds are applied to the cutting tool in the aim to test their impact on shear localization, chip segmentation, and numerical forces levels as well as to approve previous highlighted findings related to constitutive parameters definition. In general, this study focuses on a prominent decrease in identification process cost with the previous knowledge of the most affecting constitutive coefficients while keeping an interesting agreement between numerical and experimental results.