Efficient constitutive material model for predicting residual stresses induced by orthogonal cutting

This work aims to develop a finite element model (FEM) for predicting machining-induced residual stresses. The effect of the constitutive model used to describe material response on the numerical modeling of orthogonal cutting is investigated. Two constitutive material models are separately incorporated into FEM: (i) The Johnson-Cook (JC) law and (ii) the proposed model, which considers kinematicisotropic hardening with strain rate and thermal softening effects. The influence of cyclic hardening on cutting forces, chip morphologies, and residual stresses (RS) is analyzed. Although the JC law produces superior results when modeling cutting forces and chip morphologies, the proposed model provides reliable results when predicting RS profiles.