Investigations on the effects of different constitutive models in finite element simulation of machining

Finite element (FE) modeling of a machining process in current industrial practice is highly essential to model and simulate the metal cutting process before resorting to costly and time consuming experimental trials. The current work describes a FE evaluation of machining process when simulating AA7075-T6 cutting process and comparison of predicted results with experimentally determined data like, cutting force, tool-chip contact temperature and chip thickness. Machining experiments and investigations into the effect of different constitutive models such as, Johnson-Cook (JC), Zerilli-Armstrong (ZA), Arrhenius (Arr) and Norton-Hoff (NH) models in turning of aluminum alloy AA7075-T6 were carried. The numerical simulation results indicate that the adeptness of FE model in forecasting machining performance is quite acceptable and predicted results are very close to experimental results. (C) 2018 Elsevier Ltd. All rights reserved.