Assessment of Various Ductile Damage Criteria in Numerical Simulations of Machining Processes

Abstract

In the machining processes, chip removal can be performed by the applied forces. Therefore, predicting the required forces and energy is an essential challenge to reach the efficient processes. In this research, employing various ductile damage models of the continuum damage mechanics (CDM), a few machining processes such as 3D plane machining, 3D drilling, and turning are numerically simulated. Using the numerical simulations of finite element method (FEM), variations of the applied forces on the workpiece and the maximum force as well as the mechanism of chip formation during the machining processes are estimated. Besides, to assess the ductile damage models, the numerical simulation results are compared with the experimental results. The comparison reveals that the Ayada, Ayada negative, and Johnson–Cook damage criteria can accurately predict the required forces and respectively are the reliable models for numerical simulations of chip removal in the machining processes. © 2023, The Author(s), under exclusive licence to Korean Society for Precision Engineering.