Finite Element Simulation of Metal Cutting of Aluminum using Johnson-Cook Damage Model and Shear Failure Model

Abstract

This paper evaluates the use of the Johnson-Cook (J-C) damage model and the shear failure model in the Finite Element metal cutting simulations of an Aluminum alloy (Al 1100) using an FE commercial package ABAQUS. For the J-C model, the damage evolution in the model is controlled by the value of the parameter equivalent plastic displacement at failure, . The value of this parameter is provided to ABAQUS by user. It was found that the value of that parameter, in conjunction with mesh size, highly affects the chip morphology, chip ratio and analysis completion. Therefore, a compromising between the value of and the mesh size used should be done. The proper value of the depends on the mesh size in the chip zone of the model. Therefore, it is suggested to select the element size, of chip zone of the model, almost equals to the average grain size of workpiece. Then, change the values of until the obtained FE results agree well with experimentally formed chip. As an alternative to the use of J-C damage model, shear failure model was also used. The use of the shear failure model does not need a definition of a damage parameter to conduct the cutting simulations. The results obtained from the J-C damage model, with tuned , are in good agreement with those obtained using the shear failure model. However, those results are meshing dependent in both models. Therefore, qualitative comparison of the simulated chip with experimental chip is still necessary.