An Evaluation of Different Damage Models when Simulating the Cutting Process Using FEM

The current study compares two damage modeling approaches in metal cutting finite element simulations; the Johnson-Cook shear failure model and the progressive damage model. The first assumes sudden failure when the set criterion is met; however, the second relies on two criteria; one for damage initiation and another for damage evolution. Simulations were performed on AISI 1045 steel, and different process parameters (forces, chip thickness, temperatures and plastic strain) were compared. Also, dry orthogonal cutting tests were performed and cutting forces and chip thickness were compared to the predicted values. The current results showed better predictions when damage evolution was considered.