The effect of materials testing modes on finite element simulation of hard machining via the use of internal state variable plasticity model coupled with experimental study

To understand the true nature of hard turning mechanics, a numerical model that incorporates an internal state variable plasticity model via a material user subroutine has been developed with the material constants obtained from the compression and tension tests. A global material failure/damage evolution model was implemented to simulate chip formation that solely depends on the material deformation state. Orthogonal hard turning experiments were performed to validate the numerical model. The purpose of this work was to determine the material property differences under the different stress states by using numerical simulations. The numerical and experimental results illustrated that the material constants from the compression tests captured the true nature of a hard machining process as compression dominates the of material deformation process in hard machining.