Comparison of Different Flow Stress Models of the Orthogonal Metal Cutting Process Using Finite Element Analysis

This paper presents a comparative study of the effect of two different flow stress models on the orthogonal metal cutting process using the FEM. The flow stress models used were the Oxley's model and the modified Johnson and Cook model. The orthogonal cutting experiments were conducted with AISI 1045 steel work material and tungsten carbide cutting tool. The FEA results with modified Johnson's model for the cutting force, feed force, chip thickness, shear angle and shear strain compared well with the experimental values with only a marginal deviation of 10-20% for feed rates of 0.16mm/rev and above while the deviation for Oxley's model was higher across most feed rates. The Oxley model gave better results for the FE predictions of contact temperature. This study suggested that the modified Johnson and Cook model was an efficient alternative tool for FE simulation of the orthogonal metal cutting process.