The Prediction of Machined Surface Hardness Using a New Physics-based Material Model

This paper investigates the predictionof machined surface hardness, a key material property, as a direct consequence of machining induced microstructure evolution. To this end, a newphysics-based material model is implemented into the AdvantEdgeTM software via a user-defined material subroutine and used to simulate the orthogonal cutting of OFHC copper. This material model explicitly integrates the microstructure, represented by dislocation density and grain size, into the constitutive description of inelastic deformation. The associated microstructure evolution laws in conjunction with the constitutive law provide a unified microstructure-property framework in which the microstructure evolves during deformation via hardening, dynamic recovery, and dynamic recrystallization mechanisms and the evolved microstructure features are directly fed back to the flow stress model. The predicted hardness distribution in the spatial domain of deformation in orthogonal cutting is benchmarked against experimental data.