Evaluation of different flow stress laws coupled with a physical based ductile failure criterion for the modelling of the chip formation process of Ti-6Al-4V under broaching conditions

During the machining of Ti-6Al-4V the changing deformation mechanisms produce a complex microstructure of segmented chips, which directly influenced tool-wear and process stability. Numerical simulation could give an insight into the physical phenomena involved in chip segmentation, but its accuracy is directly related to the reliability of the input parameters. In this work, therefore, three different flow stress law were evaluated coupled with a physical based ductile failure criterion, which depends on stress triaxiality and temperature. To this end, the flow stress laws were implemented in the finite element software AdvantEdge by programming user-defined subroutines. The resulting FEM models were compared with orthogonal cutting experimental tests (tubular/linear), analyzing different fundamental outputs (machining forces, temperatures in the workpiece and chip morphology). All the FEM models showed good agreement with the experimental results.