Developing a 2D finite element cutting model based on individual phases in orthogonal cutting of two-phase duplex stainless steel

This paper presents a novel method to model the metal cutting of 2205 duplex stainless steel alloy. A 2D finite element model was developed to predict the plastic behaviour of two phases of duplex stainless steel, austenite, and ferrite during orthogonal cutting. A mesh based on physical microstructure was created using mapping software OOF2. The finite model was setup on ABAQUS software based on the Lagrangian method. The cutting model allows for tracking of stress and strain on individual phases during chip formation. Simulated and experimental data showed good agreement in comparison of shear angle and cutting strain. Model was created to gain understanding of long-established issues in machining duplex stainless alloys. Future model development required to gain further insight on associated triggering mechanisms.