Effect of Johnson–Cook Material Model Constants on Predicted Chip Morphology and Forces in FE Simulations of Machining Operation for 93% WHA Alloy

Tungsten heavy alloys (WHAs) with W content 90–95% possess a good combination of high tensile strength as well as high density, thus finding wide applications as counterweights and ballast, radiation shielding, ballistic penetrators, vibration-damped tooling and sporting goods. However, these properties make machining of WHAs to desired dimensions and finish very difficult. A proper understanding of the mechanism of chip formation during machining is surely required that helps in finding the right combination of cutting parameters for achieving higher productivity and better finish. Finite element (FE) simulations help understand the chip formation mechanism with minimum number of experiments. The basic purpose of the current work is to develop an FE model by taking into account three different sets of JC model constants and compare the predicted output variables with experimental machining tests available in the literature.