Effect of rake angle-based Johnson-Cook material constants on the prediction of residual stresses and temperatures induced in Al2024-T3 machining

Nowadays finite element modeling (FEM) has become a vital and irreplaceable simulation tool in studying the machining processes. The machining simulation results depend strongly on the constitutive law and the characterization methods used to determine its constants. In the present work, three different sets of Johnson-Cook (JC) constants, determined through orthogonal machining tests at different rake angles, are used in FEM to simulate the behavior of Al2024-T3 alloy under high speed machining (HSM) process. The effect of these sets on the predicted residual stresses within the machined workpiece and the temperatures of the cutting tool are the subject of a comparative investigation. It is found that the residual stress distributions are much more sensitive to these sets of JC than the temperature distributions. Additionally, it is concluded that the set of JC obtained at 0 ° rake angle, JC(0°), gives an overall more accurate prediction of the investigated parameters.