The influence of material models on finite element simulation of machining

In literature, four models incorporating strain rate and temperature effects are able to generalize material test results of HY-100 steel. This study compares the four models, namely, Litonski-Batra, power law, Johnson-Cook, and Bodner-Partom, in finite element modeling of orthogonal machining of this material. Consistency is found in cutting forces, as well as in stress and temperature patterns in all but the Litonski-Batra model. However; the predicted chip curls are inconsistent among the four models. Furthermore, the predicted residual stresses are substantially sensitive to the selection of material models. The magnitudes, and even the sign of the residual stresses in machined surfaces, vary with different models.