Numerical Simulation of Machining Processes by Using Hooputra's Shear Damage Criterion

Chip removing in the machining processes is done through the forces. Therefore, prediction of the forces and estimation of required energy is very important for determination of the efficiency of these operations. In this investigation first, by using Hooputrs’s shear damage model in the ABAQUS/Explicit code, a number of conventional machining processes such as plane milling, straight turning, face turning, and drilling are simulated. By performing the simulations, variations of the force acting on the tool, maximum force, and also chip formation mechanism in each of the above processes are predicted. Then, in order to evaluate the shear damage model and material properties, the simulation results are compared with the results of theoretical and experimental relations. Comparison of the numerical and empirical results reveal that the Hooputra’s shear damage model can well predict the damage initiation and evolution, chip formation, and forces acting on the tool in the machining processes.