Orthogonal Metal Cutting Simulation Using Advanced Constitutive Equations with Damage and Fully Adaptive Numerical Procedure

This work proposes a complete adaptive numerical methodology which uses ‘advanced’ elastoplastic constitutive equations coupling: thermal effects, large elasto‐viscoplasticity with mixed non linear hardening, ductile damage and contact with friction, for 2D machining simulation. Fully coupled (strong coupling) thermo‐elasto‐visco‐plastic‐damage constitutive equations based on the state variables under large plastic deformation developed for metal forming simulation are presented. The relevant numerical aspects concerning the local integration scheme as well as the global resolution strategy and the adaptive remeshing facility are briefly discussed. Applications are made to the orthogonal metal cutting by chip formation and segmentation under high velocity. The interactions between hardening, plasticity, ductile damage and thermal effects and their effects on the adiabatic shear band formation including the formation of cracks are investigated.