Determination of material model parameters from orthogonal cutting experiments

Flow stress models in finite element analysis of metal cutting require material parameters that are essential considering the accuracy of the simulations. This article presents a method to acquire material parameters from cutting experiments using the extended Oxley's shear zone theory. The novelty in this approach is to use measured chip geometry and temperature instead of determining them analytically to calculate strain and strain rate. These values are used to calculate the resultant cutting forces with the extended Oxley's model and Johnson-Cook flow stress model. Flow stress model parameters are optimized to fit the calculated forces to those measured from cutting experiments. The Johnson-Cook parameters acquired with this method perform better than those found in the literature.