Inverse identification of flow stress in metal cutting process using Response Surface Methodology

• A robust FEM-based methodology for inverse identification of flow stress data.
• SHPB high strain rate test data may not be suitable for metal cutting simulations.
• The proper constitutive and friction models are of vital importance.
• A marked improvement in simulation results was seen by adopting the current method.

In this study, a methodology was presented to determine the flow stress behaviour of the work material within the range of strain, strain rate and temperature encountered during chip formation process by means of inverse modelling of orthogonal cutting operations. This approach was based on the concept of Design of Experiments (DOEs) and Response Surface Methodology (RSM). Initially, an extension of Oxley’s machining theory incorporating the Johnson–Cook material model was integrated with RSM to accomplish a fast assessment of the material parameters. Having provided the material parameters by Oxley’s machining theory, the optimum set of friction coefficients were determined through evaluation of the Finite Element (FE) simulation results. The final step involved direct integration of 2D FE models incorporating the optimum frictional boundary conditions with RSM to reassess the optimum set of material parameters. This approach was implemented to determine the constitutive parameters for wide range of materials including Inconel 718 in aged condition, AISI 1080 plain carbon steel and AA6082-T6 aluminium alloy. The calibration of material models using the presented inverse methodology led to a significant improvement in simulation results. The reasons for the robustness of the proposed inverse methodology were discussed.