Abstract
Numerical simulations in machining processes are dependent on the flow stress input data. The flow stress is computed from empirical models which depend on number of material parameters, the values of which are derived from various mathematical optimization techniques. The derived flow stress parameters vary based on the nature of techniques used and the flow stress testing procedure utilized. This results in variations in the numerical simulation results when working with different models. In this work, the Johnson Cook flow stress model is tested for its sensitivity towards the finite element (FE) results. Orthogonal turning is conducted with AA 6082 (T6) aluminium alloy and the process is simulated in Deform 2D. The flow stress computed from the Johnson Cook model is input to the FE code and the cutting force and chip thickness recorded. The FE results are input to the Minitab statistical code and an optimization process conducted based on the orthogonal arrays concept. The comparative study reveals the sensitivity of the five parameters of the material model towards the cutting force and chip thickness.
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