Cutting Simulation with Consideration of the Material Hardening in the Shear Zone of AISI1045

By the use of high energy synchrotron X-ray diffraction it was possible to determine the stress state in the chip formation zone during orthogonal cutting of AISI1045. The analysis of the diffractograms showed a hardening of the material during the movement through the shear zone. For this reason nano indentation experiments on prepared chips have been carried out. With these experiments, the material hardening has been confirmed. The nano indentation experiments were reproduced by FEM simulations and it was possible to determine flow curves of the hardened material above the shear zone based on existing flow curves of AISI1045. Thus, cutting simulations have been carried out, which considered the material hardening in the shear zone. The simulation results were then compared with the results of the in-situ strain measurements.