Extracting HCP Zerilli-Armstrong material parameters for magnesium alloy AZ31B from orthogonal cutting tests

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This work reports on a methodology to extend Oxley’s analysis of the thick shear zone to account for HCP materials. Ultimately, the work extracts Zerilli-Armstrong (ZA) constitutive equation’ material parameters for AZ31B, an HCP crystal structure magnesium-based alloy. The methodology for accomplishing this utilizes three tasks namely: 1) Extension of thick shear zone approach for machining force simulation to account for Zerilli-Armstrong HCP material model, 2) measure cutting and thrust edge forces from orthogonal cutting tests (uncut chip thickness and cutting speed values varying between 0.05 and 0.4 mm/rev and 50–400 m/min, respectively), and 3) numerically determine updated material model parameters for AZ31B by minimizing the difference between the methodology-predicted forces and those experimentally measured. Comparing numerical data with the experiments, the determined AZ31B material model with updated parameters yielded predictability of R 2 of 0.94 and 0.91 for cutting and thrust forces, respectively. Additional validations were conducted by favorably comparing flow stress numerical predictions for AZ31B with literature-published histories at wide operating ranges of temperature, strain, and strain rate values. The presented methodology for finding HCP Zerilli-Armstrong material model parameters based on orthogonal cutting tests may serve as complementary alternative to time-consuming tension-compression flow stress experiments.