Prediction of serrated chip formation in orthogonal metal cutting by advanced adaptive 2D numerical methodology

In this work a complete numerical methodology combining ‘advanced’ thermo-elasto-viscoplastic constitutive equations accounting for mixed (isotropic and kinematic) non-linear hardening, thermal effects, isotropic ductile damage and contact with friction is proposed to simulate the 2D orthogonal cutting process of AISI4340 steel. First, the fully coupled constitutive equations are presented and their specificities highlighted. The relevant numerical aspects concerning both the local integration scheme as well as the global resolution strategy together with the 2D adaptive remeshing facility are discussed. This model is implemented into ABAQUS/EXPLICIT using the Vumat user subroutine and connected with an adaptive 2D meshing program. Application is made to the 2D orthogonal metal cutting by chip formation. A special care is put in the prediction of the primary shear band where the temperature, the strain and the damage are highly localised giving the serrated shape and possible segmentation of the ship.