Zones of material separation in simulations of cutting

FEM simulations of orthogonal cutting are reported in which both the Johnson–Cook (JC) constitutive relation and the Johnson–Cook separation (fracture or damage) criterion are used. Results demonstrate that the damaged regions, in which separation of material occurs at the tool tip, form thin boundary layers on the top of the machined surface and on the underside of the chip. Damage was calculated in terms of the parameters of the Johnson–Cook fracture criterion appropriate for A2024-T351 aluminium alloy. The size of the damaged layers is some 35μm and appears to be independent of the uncut chip thickness t0 over the range investigated (50More