Finite element analysis of adiabatic shear band formation during orthogonal metal cutting

Abstract

In serrated chips of difficult-to-machining materials such as medium carbon steel and titanium alloy during metal cutting process at high strain rates, the fine grain structure of the narrow shear bands which results from thermal softening due to severe deformation have been observed. However, the theories which have been developed to analyze continuous chip formation and most FEM analyses based on the conventional models such as Johnson-Cook and Zerilli-Armstrong flow stress model fail to explain the adiabatic shear band formation and the serrated chip formation. This paper discusses the characteristic of the new flow stress model in the previous investigation [1,2] and FEM simulation results to predict the serrated chip formation results are shown.